x38 Cone Manual PDF

X38 Cone Crusher
Operating and Maintenance Manual
Manufactured by: Extec Screens & Crushers Ltd

Address: Hearthcote Road
Swadlincote
Derbyshire
DE11 9DU
United Kingdom
Telephone: +44 (0)1283 212121
Fax: +44 (0)1283 226465
Parts and Service: +44 (0)8000 181945
www: http://www.extecscreens.com
Ver: BKX38-EN-00001 Operating and Maintenance Manual 25 January 2008

X38 Cone Crusher
Introduction
This document has been prepared to ensure the equipment constructed by Extec Screens & Crushers
Ltd is installed, put into use and operated efficiently and safely.
Read the manual carefully to learn how to operate and service your machine correctly. Failure to do so
could result in personal injury or damage to the equipment.
It is recommended that this manual is thoroughly understood before operating the equipment.
Operation of the X38 Cone Crusher contrary to the instructions contained in this manual or modification
to the machine without prior agreement with Extec Screens & Crushers Ltd will invalidate any
undertakings given by the manufacturer in regard to this machine.
Whilst every effort has been made to ensure the accuracy of information contained within this manual,
Extec Screens & Crushers Ltd can assume no responsibility for any errors, omissions or their
consequences. As operating conditions vary considerably, all performance data is indicative only for
the X38 Cone Crusher operated in accordance with the conditions set out in this manual.
Please contact Extec Screens & Crushers Ltd regarding any part of this manual that requires further
clarification.
A copy of this manual must be kept at the operational site for easy reference.
Extec Screens & Crushers Ltd reserve the right to change the content of this manual without prior
notice.
The information contained within this manual should be considered to be commercially confidential and
should not be released to any third party without prior consent from Extec Screens & Crushers Ltd.
Page ii Introduction Ver: BKX38-EN-00001

X38 Cone Crusher
Certificate of Conformity
Supply of Machinery Safety Regulations - Machinery Directive 98/37/EC
Serial No:
Engine Serial No:
Date of build:
Ver: BKX38-EN-00001 Certificate of Conformity Page iii

X38 Cone Crusher
98/37/EC Machinery
89/336/EMC
Name of manufacturer or supplier

Extec Screens & Crushers Ltd
Full postal address including country of origin

Hearthcote Road, Swadlincote, Derbyshire, England, DE11 9DU
Description of product
Approved design of a rock crushing machine for quarry use.
Name, type or model, batch or serial number

Type: Crusher Extec Screens & Crushers Ltd
Model: X38 cone crusher Swadlincote, Derbyshire, DE11 9DU
In built diesel
Standards used, including number, title, issue date and other relative documents
EN292-1, EN292-2, EN349, EN418, EN954-1, EN60204-1; EN55011, EN61000-4-2,
EN61000-4-3, EN61000-4-6
Place of issue Extec Screens & Crushers Ltd
Name of authorized representative Andy Hall
Position of authorized representative Production Manager
Declaration
I declare that the above information in relation to the supply / manufacture of this product, is in
conformity with the stated standards and other related documents following the provisions of the
above Directives and their amendments.
Signature _____________________ Date
Page iv Certificate of Conformity Ver: BKX38-EN-00001

X38 Cone Crusher
Contents
Operating and Maintenance Manual

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Certificate of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Safety Instructions
1.1 Safety Esstentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Signs and Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety Hazards Pertaining to the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Symbols for Mandatory Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.2 Symbols for Prohibited Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.4 Machine Legend Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Component Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Features for Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Environmental Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.1 Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.2 Machine Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7.1 Entanglement Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7.2 Required Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 Measure Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.10 Organisational Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.11 Personnel Qualifications, Requirements and Responsiblities . . . . . . . . . . . . . 10
1.12 Safety Advice Regarding Specific Operational Phases. . . . . . . . . . . . . . . . . 11
1.12.1 Standard Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12.2 Blockage or Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12.3 Unguarded Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.13 Special Work, Including Equipment Maintenance and Repairs During Opera-
tion, Disposal of Parts, and Hazardous Materials. . . . . . . . . . . . . . . . . . . . . . . 12
1.13.1 Securing the Equipment Before Performing Maintenance. . . . . . . . . 12
1.13.2 Maintenance Site Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.13.3 Replacement & Removal of Components . . . . . . . . . . . . . . . . . . . . . 13
1.13.4 Climbing, Falling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.13.5 Safety Considerations During Maintenance. . . . . . . . . . . . . . . . . . . . . 14
Ver: BKX38-EN-00001 Contents Page v

X38 Cone Crusher
1.13.6 Safety Considerations During Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 14

1.13.7 Removal of Safety Devices and Guards . . . . . . . . . . . . . . . . . . . . . . . . 15
1.13.8 Surrounding Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.13.9 Safety When Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.14 Specific Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.14.1 Electrical Energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.14.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.14.3 Gas, Dust, Steam, Smoke and Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.14.4 Welding or Naked Flames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.14.5 Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.14.6 Hazardous Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Transportation
2.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Machine Transportation Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Preparing the Machine for Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Removing Tractor Unit and Bogie - (Where fitted) . . . . . . . . . . . . . . . . . . . . . 27
2.5 Tracking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6 Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Description and Technical Information

3.1 Application & Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 Key Features of the X38 Cone Crusher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5 Common Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6 Machine Layout Indicating Main Components . . . . . . . . . . . . . . . . . . . . . . . 35
3.7 Machine Layout Indicating Emergency Stop Positions . . . . . . . . . . . . . . . . . 36
3.8 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Consumption Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.9 Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Commissioning and Operation

4.1 Pre-Start Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Main Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.1 Electrical Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.2 Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.3 Engine Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Page vi Contents Ver: BKX38-EN-00001

X38 Cone Crusher
4.3.1 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.4 Stopping the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5 Stopping Machine in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.5.1 Emergency Stop Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6 Preparing the Crusher for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7 Operating The Machine (Crushing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.7.1 Loading Material Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7.2 Feeder Cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.8 Feeding the Cone Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.9 Setting Material Output Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.10 Using Remote Pendent For Setting Material Output Size . . . . . . . . . . . . . . . . 54
4.10.1 Setting Material Output Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.11 Access The Cone Crusher’s Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.12 Cone Crusher Motor Control Block Pressure Adjustment . . . . . . . . . . . . . . . . 56
4.12.1 Start Up Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.12.2 Brake Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Machine Maintenance
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 Daily Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2.1 Air Cleaner Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.3 Weekly Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3.1 Checking/ Changing Hydraulic Tank Air Breather. . . . . . . . . . . . . . . . 63
5.3.2 Greasing Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3.3 Inspecting/ Adjusting Belt Sealing Rubbers. . . . . . . . . . . . . . . . . . . . . . 65
5.3.4 Adjusting Belt Scraper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.3.5 Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.3.6 Changing Hydraulic Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.4 250 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.5 1000 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5.1 Changing Oil in Tracks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.6 Track Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.6.1 Increasing The Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.6.2 Releasing The Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.7 Oils And Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.8 Crusher Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Trouble Shooting Guide

6.1 Test Procedures for Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Checking Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.3 Checking 5 Station Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Ver: BKX38-EN-00001 Contents Page vii

X38 Cone Crusher
Parts Manual (see book Ver: BKX38-EN-00001) ....................................................................83-176
OEM Manuals supplied with this machine . . . . . . . . . . . . . 177

Eriez Metalarm MA300 Series Metal Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Siemens SITRANS Probe LU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
........................................................................ 210
........................................................................ 211
........................................................................ 212
........................................................................ 213
........................................................................ 214
........................................................................ 215
........................................................................ 216
........................................................................ 217
........................................................................ 218
........................................................................ 219
........................................................................ 220
........................................................................ 221
........................................................................ 222
........................................................................ 223
........................................................................ 224
Models 38, 44, 52, 57 and 68 SBS Cone Crushers

Safety
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Page viii Contents Ver: BKX38-EN-00001

X38 Cone Crusher
PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Features and Specifications
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
DESIGN & CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
EXTERNAL DIMENSIONS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Crusher Installation
RECEIVING THE SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
CRUSHER LIFTING AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
CRUSHER FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
CLEARANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
UPPER FRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
FEED ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
INSTALLING THE OIL LUBRICATION SYSTEM AND HYDRAULIC POWER UNIT . . . . . . . . . 269
MOTOR & DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
DIESEL ENGINE PREPARATION
(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
NEW CRUSHER BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Lubrication System, Installation and Assembly
LUBRICATION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
LUBRICATION SYSTEM ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
ELECTRICAL INTERLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
LUBRICATION COMPONENT ID CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
LUBRICATION SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
LUBRICATION SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
ALARM INSTALLATION AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
SENSOR SWITCH SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
ELECTRICAL HOOKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
LUBRICATION SYSTEM - FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
LUBRICATION SYSTEM INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
ALARM AND INTERLOCK CHECKLIST
Telsmith Gyrasphere Crushers
Lubrication System Operation and Maintenance
LUBRICATION SYSTEM DAILY START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
LUBRICATION SYSTEM OPERATING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 312
LUBRICATION SYSTEM SCHEDULED MAINTENANCE CHART . . . . . . . . . . . . . . . . . . 314
Lubrication System Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . 316
LUBRICATION SYSTEM SEASONAL STORAGE OR LONG TERM STORAGE . . . . . . . . . . . 323
Lubrication System Troubleshooting
Ver: BKX38-EN-00001 Contents Page ix

X38 Cone Crusher
LUBRICATION SYSTEM TROUBLESHOOTING SAFETY PRECAUTIONS . . . . . . . . . . . . . . 326

PRELIMINARY CHECKS & INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
LUBRICATION SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 326
Oil Pump Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Hydraulic System Overview
HYDRAULIC POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
HYDRAULIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Hydraulic System Installation and Operation
SHIPMENT DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
HYDRAULIC SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
HYDRAULIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
DIGITAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Hydraulic System Maintenance
HYDRAULIC SYSTEM MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . 360
HYDRAULIC SYSTEM MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . 364
DEPRESSURIZING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
HYDRAULIC POWER UNIT MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . 366
RELIEF CYLINDER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
POWER ROTATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
ANTI-SPIN AIR BLEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
BUTTRESS THREAD LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Hydraulic System Troubleshooting
HYDRAULIC SYSTEM TROUBLESHOOTING SAFETY . . . . . . . . . . . . . . . . . . . . . . . 386
DEPRESSURIZING THE POWER ROTATOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 387
DISCONNECTING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
PRELIMINARY CHECKS & INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
HYDRAULIC SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . 390
ELECTRICAL COMPONENT AMPERAGE CHECKS . . . . . . . . . . . . . . . . . . . . . . . 392
V-Belt Drive Adjustment and Maintenance
V-BELT DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
V-BELT CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
V-BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
V-BELT TENSION - CHECK & ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
MEASURING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
DRIVE MOTOR LUBRICATION & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 400
Models 38-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
APPENDIX B - Hydraulic System Anti Spin Components
Wear Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
HOW TO CONTACT EXTEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
REQUESTING SERVICE ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
FINDING MODEL AND SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Foreword
OPERATION AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 408
SERVICE BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Safety
Page x Contents Ver: BKX38-EN-00001

X38 Cone Crusher
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
CRUSHER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
QUARRY SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
General Instructions
WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
HYDRAULIC SYSTEM SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Support Bowl and Concave Ring
GENERAL SHUTDOWN PROCEDURE (Before Working on Crusher) . . . . . . . . . . . . . . 431
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
SUPPORT BOWL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
MIXING AND POURING SMITHBOND (Concave Ring) . . . . . . . . . . . . . . . . . . . . 445
SUPPORT BOWL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
DETERMINING THE BUTTRESS THREAD STYLE . . . . . . . . . . . . . . . . . . . . . . . . . . 447
SUPPORT BOWL INSTALLATION
(Early Style Buttress Threads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
(Late Style Buttress Threads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
RECEIVING HOPPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
FINAL INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Mantle and Head
GENERAL SHUTDOWN PROCEDURE (Before Working on Crusher) . . . . . . . . . . . . . . 457
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
HEAD & SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
MANTLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
MANTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
MIXING AND POURING SMITHBOND (Mantle) . . . . . . . . . . . . . . . . . . . . . . . . . 468
CHECKING FOR ANTI-SPIN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
HEAD AND SHAFT INSTALLATION
(Crushers Without Anti-Spin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
(Crushers With Anti-Spin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
FINAL INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Appendix B - Conversion Tables
Appendix A - Torque Tables
Ver: BKX38-EN-00001 Contents Page xi

X38 Cone Crusher
Appendix C - Weights
Appendix D - Lubricants
Appendix E - Sealants and Compounds
Appendix F - Removal Clearances
Appendix G - Wear Liner Wear Limits
CONCAVE RING WEAR MEASURMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
MANTLE WEAR MEASURMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Heavy Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 577
Page xii Contents Ver: BKX38-EN-00001

X38 Cone Crusher
Section 1 Safety Instructions
To ensure maximum safety, ALWAYS read this section carefully BEFORE operating, doing any
work or making any adjustments on the equipment.
1.1 Safety Esstentials
a. Breathing or inhaling tiny silica dust particles will cause death or serious injury.
ALWAYS work with a respitator approved by the respirator manufacturer for the job
you are doing.
b. This equipment is manufactured in accordance with the Machinery Directive 98/37/

EC.1 The customer should make sure that this equipment is in conformance with
local and national legislation if used outside of the EU.
c. Read this manual and familiarize yourself with any associated documentation. If in
doubt ask. Do not take personal risk.
d. Only trained personnel should be allowed to install, set, operate, maintain, and
decommission this equipment. Make sure that a copy of this manual is available for
any persons installing, using, maintaining or repairing this equipment.
e. Training should be provided to make sure that safe working practices are followed.
Initial commissioning and starting must only be undertaken by a competent person
who has read and fully understands the information provided in the manual pack.
ALWAYS follow the procedures outlined in the operating and maintenance
instructions.
1. Directive 98/37/EC of 22.06.98 (OJ n° L 207 of 23.07.98, p.1)
Ver: BKX38-EN-00001 Safety Instructions Page 1

X38 Cone Crusher
f. To avoid the risk of electric shock, ALWAYS isolate this equipment from the supply
source before removing any guards or covers or performing any maintenance or
adjustment to the equipment.
Note: The manufacturer declines all responsibility for injury or damage if the instructions
and precautions in this manual are not followed.
1.2 Safety Signs and Labels
a. The term "DANGER" indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
b. The term "WARNING" indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
c. All electrical control boxes are labeled. Make sure that these labels remain in place
and are clearly visible at all times.
d. Other hazards identified within this manual may also be marked on the equipment
with safety labels. Make sure that these safety labels remain in place and are
clearly visible at all times.
1.3 Safety Hazards Pertaining to the Equipment
The following safety symbols may be posted on the equipment or contained in the
manuals. You MUST observe all safety symbols, labels, and instructions.
a. MAKE SURE that safety instructions and safety labels attached to the equipment
are ALWAYS complete and perfectly legible.
b. Keep safety instructions and safety labels clean and visible at all times.
c. Replace any illegible or missing safety instructions and safety labels with new ones
before operating the equipment. See “Stickers - English” on page 168 in this
manual for part numbers.
d. Make sure replacement parts include safety instructions and labels.
Page 2 Safety Instructions Ver: BKX38-EN-00001

X38 Cone Crusher
1.3.1 Symbols for Mandatory Actions
Wear Safety Gloves Wear Eye Protection Wear Safety Helmet
Wear Safety Harness Wear Ear Protection Wear Safety Boots
Wear Close Fitting Overalls Wear Dust Mask Wear High Visibility Vest
Disconnect Power Source From Switch Off and Lockout

Wear Respirator
Supply Equipment
Read the Manual

X38 Cone Crusher
1.3.2 Symbols for Prohibited Actions
No Climbing No Smoking Do Not Touch
No Open Flames Limited or Restricted Access Do Not Weld
Do Not Remove Safety Guard
1.3.3 Hazard Symbols
Crushing Hazard - Hands Crushing Hazard - Feet Chemical Burn Hazard
Electrical Shock/Electrocution
Electrical Hazard Emtanglement Hazard
Hazard

X38 Cone Crusher
Entanglement Hazard Falling Hazard Falling Load Hazard
Hazardous or Poisonous Material

Flammable Hazard Flying Material Hazard
Hazard
Lifiting Hazard Skin Injection Hazard Silica or Other Dust Hazard
Trip Hazard Magnet Hazard

X38 Cone Crusher
1.3.4 Machine Legend Plate
1.4 Component Safety Features
a. DO NOT use this equipment if any safety guards or devices have been removed or
are installed improperly.
b. Operating this equipment with any safety guards or devices which have been
removed or installed improperly could result in death or serious injury.
1.5 Features for Operator Safety
a. Safety features associated with this equipment have been assessed in accordance
with BS EN 954-1 to Category 3.
b. Emergency Stop buttons have been installed to prevent death or serious injury.
Make sure that the Emergency Stop buttons are visible and are not obstructed in
any way.
c. The Emergency Stop circuit is a 24 V DC series circuit and hard wired to remove
power from the ECU Engine management system and stop the engine. To avoid
electric shock or cutting injury, you MUST wait at least ten full seconds after
activating the Emergency Stop to allow the system to release its electrical
charge.
d. You MUST study the detailed Safety Circuit diagram which is within the drawing
pack as an appendix to this manual.

X38 Cone Crusher
e. Safety guards have been installed to prevent death or serious injury. DO NOT
remove, modify, or alter any safety guard. Make sure that all safety guards are
bolted down.
f. Steps, handrails, tread plates, and fixed guards are provided where personnel are
required to climb on the machine.
g. If for any reason other areas of the machine need to be accessed, risks MUST be
assessed and appropriate safety measures taken.
1.6 Environmental Safety
To avoid unnecessary engine emissions, you MUST regularly service the machine as specified
in the machine maintenance sections contained in this manual.
1.6.1 Hazardous Materials
WARNING
• Potentially harmful waste used
on this equipment includes
items such as oil, fuel, coolant,
filters, batteries, etc.
• DO NOT store harmful waste
in food or beverage containers
that may mislead someone
into drinking from them, which
could cause death or serious
injury
• Use leak proof containers
when draining fluids
• DO NOT pour waste onto the
ground, down a drain or into
any water source.
a. Diesel spillages MUST be cleaned up immediately due to fire hazard.
b. ONLY use the lubricating oils recommended in the maintenance schedule.
c. OBSERVE the COSHH information contained in the appendix to this manual.

X38 Cone Crusher
d. Local & National regulations MUST be observed when disposing of waste.
e. Improperly disposing of waste CAN THREATEN the environment and ecology and
is illegal.
f. MAKE SURE that all hazardous and replaced parts are disposed of safely and with
minimum environmental impact.
1.6.2 Machine Disposal
This equipment MUST ONLY be disposed of at a specialist machine breaker.
1.7 Personal Protective Equipment (PPE)
1.7.1 Entanglement Hazards
DANGER
1. Loose clothing, tools, jewelry,
long hair, or body parts can
get caught in running
machinery, which will result in
death or serious injury.
2. ALWAYS wear correctly fitting
(CE approved) personal
protective equipment.
Garments must be close fitting
and no jewelry such as rings
may be worn.
3. DO NOT work close to
machinery unless it is stopped.
1.7.2 Required Personal Protective Equipment
This includes:
• Hard Hat
• Safety Glasses/Goggles
• Hearing Protection

X38 Cone Crusher
• Dusk Mask
• Close Fitting Overalls
• Safety Boots
• Industrial Gloves
• High Visibility Vest or Jacket
• Respirator
1.8 Measure Noise Level
Ear protection must be worn if you are within 10 meters (approximately 33 feet) of
the machine when the engine and other parts of the machine are running.
86 dB 90 dB 88 dB 86 dB
7m
87 dB 93 dB 98 dB 89 dB
1m
87 dB
82 dB
85 dB
79 dB
1m
87 dB 92 dB 95 dB 89 dB
7m
85 dB 90 dB 88 dB 86 dB
Figure 1-1: Measured Noise Level
The above diagram indicates the measured noise levels at a measured distance; i.e. 7 m
(approximately 23 feet) - 85 dB indicates that at 7 meters the sound measured was 85 decibels.
The readings were measured using a Castle GA101/701 meter with a calibration date of //TBD/

X38 Cone Crusher
/ and with all systems running situated on the factory assembly line. The product and local
conditions will affect the noise levels.
1.9 Vibration Levels
There are NO circumstances where an operator needs to be on or touching the machine

when it is running.
1.10 Organisational Safety Measures
The following safety measures MUST be observed at all times:
• Understand the service procedure before doing work. Keep area clean and dry.
• NEVER lubricate, clean, service, or adjust machinery while it is moving.
• Allow the machinery to cool before performing any maintenance or adjustments.
• MAKE SURE that all parts are properly installed and are in good condition.
Replace worn and broken parts IMMEDIATELY.
• Remove any build up of grease, oil and debris from equipment.
• Disconnect battery ground cable before making adjustments on electrical systems
or welding on the equipment.
• During maintenance ONLY use the correct tool for the job.
• NEVER make any modifications, additions, or conversions which might affect safety
without the manufacturer's approval.
• If clothing, tools, or any body parts become entangled in machinery, IMMEDIATELY
disengage all power and operate controls to relieve pressure. Stop the engine and
implement lockout procedures.
• If the equipment exhibits any unusual movement or sound, stop the equipment, lock
out IMMEDIATELY, and report the malfunction to a competent authority or
personnel.
1.11 Personnel Qualifications, Requirements and Responsiblities
a. All work involving the equipment MUST ONLY be performed by trained, reliable
and authorized personnel only. Statutory minimum age limits must be observed.
b. Work on electrical system and its equipment MUST ONLY be carried out by a
skilled electrician or by instructed persons under the supervision and guidance of a

X38 Cone Crusher
skilled electrician and in accordance with electrical engineering rules and

regulations.
c. Work on the hydraulic system MUST ONLY be carried out by personnel with
special knowledge and experience of hydraulic equipment.
1.12 Safety Advice Regarding Specific Operational Phases
1.12.1 Standard Operation
a. Take the necessary steps to make sure that the equipment is used ONLY when it is
in a safe and reliable state.
b. Operate the equipment ONLY for its designed purpose, and only if all guarding,
protective, and safety devices, emergency shut-off equipment, sound proofing
elements and exhausts, are in place and fully functional.
c. MAKE SURE that any local barriers are erected to stop unauthorized entry to the
equipment.
d. BEFORE starting the engine make sure that it is safe to do so.
1.12.2 Blockage or Malfunction
In the event of material blockage, any malfunction or operational difficulty, stop the
equipment and lockout immediately. Repair any defects or hazardous conditions
immediately.
1.12.3 Unguarded Areas
a. Limit access to the equipment and its surrounds by erecting barrier guards to
reduce the risk of other mechanical hazards, falling loads and ejected materials.

X38 Cone Crusher
b. Switch off and lockout the equipment before removing any safety devices or
guarding.
DANGER
• To avoid death or serious
injury, ALWAYS keep your
hands and other body parts
away from pinch points on the
machine.
• DO NOT reach into unguarded
machinery.
1.13 Special Work, Including Equipment Maintenance and Repairs During

Operation, Disposal of Parts, and Hazardous Materials
a. Observe the adjusting, maintenance, and service intervals set out in the operating
instructions, except where:
• Warning horns, lights, gauges, or indicators call for immediate action; or

• Adverse conditions require more frequent servicing.
b. ALWAYS only use Original Equipment Manufacturer's ("OEM") recommended
replacement parts and equipment.
c. Make sure that only properly trained personnel undertake these tasks.
1.13.1 Securing the Equipment Before Performing Maintenance
When undertaking maintenance and repair work, the equipment must first be made
safe.
a. Switch off the engine using the ignition key. Switch off at isolation point and remove
the ignition key.

X38 Cone Crusher
b. Implement lockout procedures.
c. Attach a hazard sign(s) to the equipment in appropriate positions to alert all

personnel of potential hazards.
1.13.2 Maintenance Site Conditions
Prior to starting any maintenance work, MAKE SURE the equipment is positioned on
stable and level ground and has been secured against inadvertent movement and
buckling.
1.13.3 Replacement & Removal of Components
a. ALWAYS observe handling instructions itemized in this manual, the Original

Equipment Manufacturer's manuals, or the spare parts suppliers' instructions.
b. NEVER allow untrained staff to attempt to remove or replace any part of the
equipment.
c. The removal of large or heavy components without adequate lifting equipment is

PROHIBITED.
d. To avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be carefully attached to lifting tackle and secured.
ONLY use suitable and technically adequate lifting gear supplied or approved by
Original Equipment Manufacturer.
e. NEVER work or stand under suspended loads.
f. KEEP AWAY from the feeder hopper and product conveyor discharge, where there
is risk of serious injury or death from contact with ejected debris.
g. LIMIT ACCESS to the equipment and its surrounds by erecting barrier guards to
reduce the risk of residual mechanical hazards, falling lifted loads, and ejected
materials.
1.13.4 Climbing, Falling
a. Falling from and/or onto this equipment could result in death or serious injury.
b. NEVER climb on the equipment while it is in operation or use equipment parts as a

climbing aid.
c. ALWAYS keep the area around the equipment clear of debris and trip hazards.

X38 Cone Crusher
d. Beware of moving haulage and loading equipment in the vicinity of the equipment.
e. For carrying out overhead assembly work, ALWAYS use specially designed or
otherwise safety-oriented ladders and working platforms.
f. ONLY use walkways/platforms provided on the equipment. ALWAYS perform work

from an approved, safe and secure platform.
g. When reaching any points 2m (approximately 6 feet) or more above the ground
level, ALWAYS use CE certified safety harness.
h. Keep all handles, steps, handrails, platforms, landing areas, and ladders free from
dirt, oil, snow and ice.
1.13.5 Safety Considerations During Maintenance
It is essential that you take the following steps to MAKE SURE you and others are
safe.
a. During maintenance, RESTRICT ACCESS to essential staff only. Where

appropriate, erect barrier guards and post warnings.
b. The fastening of loads and instructing or guiding of crane operators should be

entrusted to qualified persons only.
c. The marshal providing instructions must be within sight or sound of the operator
and positioned to have an all around view of the operation.
d. ALWAYS make sure that any safety device such as locking wedges, securing
chains, bars, or struts are utilized as indicated in these operating instructions.
e. Make sure that any part of the equipment raised for any reason is prevented from
falling by securing it in a safe reliable manner.
f. NEVER work under unsupported equipment.
g. NEVER work alone.
1.13.6 Safety Considerations During Cleaning
a. This equipment MUST be isolated prior to cleaning.
b. DO NOT direct power washers near or into control boxes and devices.

X38 Cone Crusher
c. After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found MUST be repaired
immediately.
1.13.7 Removal of Safety Devices and Guards
a. Prior to operation, all safety devices (control devices or guards) temporarily

removed for set-up, maintenance or repair purposes MUST be refitted and checked
immediately upon completion of the maintenance and repair work.
b. To avoid serious personal injury or death, NEVER operate the equipment with
safety devices or guards removed or unsecured.
c. ALWAYS report any defects regarding guards, safety devices or control devices.
1.13.8 Surrounding Structures
a. This equipment MUST ONLY be operated in a position away from buildings,

permanent structures or high ground to eliminate the risk of persons falling onto the
equipment or its surrounds.
b. Any temporary structures erected around the equipment MUST be removed prior to
operation.

X38 Cone Crusher
1.13.9 Safety When Refueling
WARNING
• Diesel fuel is flammable and
creates a potential hazard
which could result in death or
serious injury.
• To avoid spillages use drip
trays.
• ONLY refuel with diesel from
approved storage and supply
equipment.
• NEVER remove the filler cap
or refuel with the engine
running.
• NEVER add gasoline or any
other fuels mixed to diesel due
to increased fire or explosion
risks and damage to the
engine.
• Smoking is PROHIBITED
when refueling or handling
diesel fuel.
• DO NOT carry out
maintenance on the fuel
system near naked lights or
sources of sparks, such as
welding equipment.
• IMMEDIATELY clean up spilt
fuel and dispose of correctly to
minimize any environmental
impact.

X38 Cone Crusher
1.14 Specific Hazards
1.14.1 Electrical Energy
A. External Considerations and Hazards
When working with the equipment, maintain a safe distance from overhead electric lines.
If overhead cables are in the vicinity, a risk assessment MUST be completed prior to
operating the equipment
DANGER
Contact with overhead electric lines
will cause death or serious injury.
If your equipment comes into contact

with a live wire, you MUST:
• Vacate the area;
• Warn others against
approaching and
touching the equipment;
• Report the incident and
have the live wire shut
off.
B. Machine - Electrical
1. Work on the electrical system or equipment MUST ONLY be carried out by a skilled
and qualified electrician or by specially instructed personnel under the control and
supervision of such an electrician and in accordance with applicable electrical
engineering rules.
2. Before starting any maintenance or repair work, the power supply to the equipment
MUST be isolated. Check the de-energized parts to make sure they do not have
any power. In addition to insulating any adjacent parts or elements, ground or short
circuit them to avoid the risk of electrical shock.
3. The electrical equipment is to be inspected and checked at regular intervals.
Defects such as loose connections or scorched or otherwise damaged cables
MUST be fixed immediately.
4. Use ONLY original fuses with the specified current rating. Switch off the equipment
IMMEDIATELY if trouble occurs in the electrical system.
5. This equipment is wired on a negative earth. ALWAYS observe correct polarity.

X38 Cone Crusher
1.14.2 Battery
a. ALWAYS disconnect battery leads before carrying out any maintenance to the
electrical system.
b. Recharge the battery in a well ventilated area.
c. The battery contains sulphuric acid, an electrolyte which can cause severe burns
and produce explosive gases.
d. AVOID contact with the skin, eyes or clothing.
e. Smoking is PROHIBITED when maintaining the battery.
f. ALWAYS wear appropriate personal protective equipment.
1.14.3 Gas, Dust, Steam, Smoke and Noise
a. ALWAYS operate internal combustion engines outside or in a well ventilated area.
b. If, during maintenance, the equipment must be operated in an enclosed area,

MAKE SURE that there is sufficient ventilation or provide forced ventilation.
c. Observe the regulations in force at the respective site.
d. Dust found on the equipment or produced during work on the equipment MUST
NOT be removed by blowing with compressed air.
e. Dust waste MUST ONLY be handled by authorized persons. When disposing of

dust waste, the material must be dampened, placed in a sealed container and
marked to ensure proper disposal.
f. Breathing or inhaling tiny silica dust particles will cause death or serious injury.
ALWAYS work with a respitator approved by the respirator manufacturer for the job
you are doing.

X38 Cone Crusher
1.14.4 Welding or Naked Flames
WARNING
• Welding or naked flames on or
around the equipment creates
the risk of an explosion or fire,
which could result in death or
serious injury.
• AVOID all naked flames in the
vicinity of this equipment.
• Welding, flame cutting and
grinding work on the
equipment MUST ONLY be
carried out if this has been
expressly authorized, as there
may be a risk of explosion and
fire.
• Before carrying out welding,
flame cutting and grinding
operations, clean the
equipment and its
surroundings from dust and
other flammable substances
and make sure the premises
are adequately ventilated, as
there may be a risk of
explosion
• The battery MUST BE
isolated.

X38 Cone Crusher
1.14.5 Hydraulic Equipment
a. Work on hydraulic equipment must be carried out by persons having special

knowledge and experience of hydraulic systems.
WARNING
• Splashed oil creates the risk of
a fire, which could result in
• Check all lines, hoses and
screwed connections regularly
for leaks or other damage.
• Repair damaged lines, hoses,
or screwed connections
IMMEDIATELY.
b. ALWAYS relieve pressure from the hydraulic system before carrying out any kind
of maintenance or adjustment.
c. BEFORE carrying out any repair work, depressurize all system sections and
pressure pipes (i.e. hydraulic system, compressed air system, etc.) requiring
removal, in accordance with the specific instructions for the unit concerned.
d. Hydraulic and compressed air lines MUST be laid and fitted properly. Make sure
that no connections are interchanged. The fittings, lengths and quality of the hoses
MUST comply with the technical requirements.
e. ONLY fit replacement components of a type recommended by the manufacturer.
f. ALWAYS practice extreme cleanliness when servicing hydraulic components

X38 Cone Crusher
DANGER
• Hydraulic fluid under pressure
can penetrate the skin, which
will result in death or serious
injury.
• If fluid is injected under the
skin, it must be surgically
removed or gangrene will
result. GET MEDICAL HELP
IMMEDIATELY.
• ALWAYS use a piece of
cardboard to check for leaks.
DO NOT USE YOUR HAND.
1.14.6 Hazardous Substances
a. MAKE SURE that correct procedures are formulated to safely handle hazardous
materials in strict accordance with the manufacturer's instructions and all applicable
regulations by correctly identifying, labeling, storing, using and disposing of the
materials.
b. A full list of Hazardous Substances associated with this equipment can be found in
the appendix of this document.

X38 Cone Crusher
Intentionally left blank

X38 Cone Crusher
Section 2 Transportation
2.1 Transport
This machine must only be transported between sites on a suitable low loader or by utilising the
optional bogie/ fifth wheel where available.
The machine must be tracked onto and off the trailer. See “Tracking Procedure” on page 29
Note: This equipment must never be tracked on gradients that are more than: 10 degrees
Port to Starboard or 20 degrees Front to Back. The machine must always be on flat,
solid ground when operating in its normal mode.
A bogie and fifth wheel is available as an optional extra. The fifth wheel fits at the rear (slew
conveyor) end of the machine and attaches directly to the back of a tractor. The bogie fits at the
front of the machine underneath the main conveyor. This is installed by lowering all four jacking
legs to lift the machine off the ground allowing the bogie to be rolled into position. When in
position the machine is lowered until all four brackets align and locks the bogie into position. If
this option is chosen full instructions may be found in the applicable section.
Ensure the loading/ unloading site is clear of non essential personnel. Barrier the area and post
warning signs where site conditions warrant this.
Loading/ unloading must only be carried out on firm flat ground.
The operator must be fully trained in the operation of this equipment.
When tracking, the operator must be in a position to have an all round view of the operation. A
banks man or marshal should assist where this is not possible.
The total weight of this machine is 48 tonnes (without the bogie).
Before transporting on the road, the load dimensions must be checked to

ensure that they are within the legal transport limits.
Ver: BKX38-EN-00001 Transportation Page 23

X38 Cone Crusher
2.2 Machine Transportation Dimension
Transport Width
2741m
Figure 2-1: X38 Cone Crusher Transport Dimensions
Ensure that feeder is slewed into the transport position (as above),
and the spray bar is folded prior to transportation.
2.3 Preparing the Machine for Transportation
1. Ensure that all materials have run off the conveyor belts and that the hopper is empty.
DO NOT FOLD ANY CONVEYORS UNLESS MOVING PARTS ARE

STOPPED.
Ensure that:
2. All belt retention straps have been fitted.
3. Check and if necessary inflate/ deflate the tyre pressures to the tyre manufacturer’s
recommendations.
4. All loose parts have been secured.
5. The engine must be switched off.
Page 24 Transportation Ver: BKX38-EN-00001

X38 Cone Crusher
6. Machine is cleaned off loose debris.
REMEMBER, THE DRIVER IS RESPONSIBLE FOR HIS LOAD & WHAT

HE IS TOWING.
1: Feeder conveyor lower lever. 2: Lower feeder conveyor into transport position.
3: Fold light stand into transport position as

indicated above. (Where fitted.)
4: Lower the feeder conveyor’s side doors 5: Lower the feeder conveyor’s rear door

X38 Cone Crusher
6: Secure subframe telescopic leg. (Where fitted.) 7: Secure support arm. (Where fitted.)
8: Remove the bolts and stow the rock box in the 9: Remove the bolts of the sonar stand a
feeder. secure it to the walkways. (Where fitted.)

X38 Cone Crusher
2.4 Removing Tractor Unit and Bogie - (Where fitted)
• Find a level and firm piece of ground (of suitable size and location). See “Starting
Procedure” on page 43 on how to start the engine.
1: Remove jacking leg retention screws.
Note: Before attempting to lower the jacking legs ALL of the leg transportation retaining screws
MUST be removed.
3: Lower front jacking legs to raise fifth wheel

2: Front jacking legs lever.
neck by approximately 100 mm.
4: Remove tractor unit air brakes & lighting

5: Unlock bogie from machine (4 positions).
connections then unhitch from machine.

X38 Cone Crusher
7: Lower rear jacking legs to raise machine

6: Rear jacking legs lever.
clear of the bogie locking mechanism.
8: Remove bogie air brakes & lighting 9: Retract both front and rear jacking legs so
connections then tow away from machine. that weight of machine is taken on tracks.
10: Remove connection panel & umbilical cord completely from machine.
Fitting the bogie and attaching the tractor for transportation is a reversed procedure to that
describe above.
IMPORTANT: Before transporting with the bogie fitted ensure that the jacking legs
are fully retracted and the leg transportation retaining screw have been refitted and
tightened to prevent the legs from dropping.

X38 Cone Crusher
2.5 Tracking Procedure
The X38 Cone Crusher can now be manoeuvred using either the remote handset or hard wire
drive to move machine to desired position.
WARNING: BEFORE TRACKING THIS MACHINE IT IS IMPORTANT THAT THE FOLLOWING IS
ADHERED TO:
1. The slew conveyor hopper MUST be empty of material.

2. The chassis jacking legs MUST be retracted. See below.
3. The towing bogie is unhitched. See “Removing Tractor Unit and Bogie - (Where fitted)”
on page 27.
4. See “Starting Procedure” on page 43 on how to start the engine.
When engine is running at speed No.1, the machine can be moved to desired position on site
by following the procedures in the order listed below:
3: Activate levers to raise front

1: Press button clamp on. 2: Press button interlock on. jacking legs.
4: Activate levers to raise rear

jacking legs.
5: Jacking legs fully raised 6: Press button tracks on.
tracks on disables other hydraulic functions.
After following instructions on the previous page, use either the Remote Handset or Hard Wire
Drive to move machine to desired position.

X38 Cone Crusher
Note: The white remote handset is supplied with the machine and must be fully recharged
at regular intervals. Use the correct instructions for your type of controller.
3: Plug in Hard Wire

1: Remote Handset 2: Umbilical Cord 4: Hard Wire Handset
Umbilical Socket
WARNING: Under NO circumstances try to move the machine when engine speed is
set at position No.2 or when ANY personnel are standing on the machine.
For safety reasons, it is essential to check all around machine for obstacles or personnel which
may be endangered by moving the machine.
When moving machine, ensure that it is only moved over firm ground suitable for carrying the
weight of the machine. Prior to operating the machine, it is ESSENTIAL that both tracks are in
contact with firm level ground to avoid excessive vibration or rocking of the machine. DO NOT
MOVE THE MACHINE ACROSS EXCESSIVELY SLOPING GROUND.
Note:
1. When operating the White Remote Handset, the yellow buttons are for forward
movement and the blue ones for reverse. (These correspond to direction indicator
stickers on the machine.)
2. When operating the Hard Wire Handset, the yellow buttons are for forward movement
and the blue ones for reverse. (These correspond to direction indicator stickers on the
machine.)
DE1007
When the machine is moved to its desired operating position, prepare the crusher for operation
by following the procedures laid out in the following pages.

X38 Cone Crusher
2.6 Loading the Machine
DO NOT MOVE THE MACHINE WITHOUT ALL TRANSPORTATION FITMENTS SECURELY

IN POSITION AND SAFETY PINS IN PLACE.
1. In all conditions, especially wet weather, rubber matting is essential on the ramps and
incline of the trailer. This will prevent skidding and sudden misalignment whilst climbing
on to the trailer.
2. When you are confident to proceed manoeuvring onto the trailer, keep the machine
travelling up the ramps and over the peaks in one full motion. Hesitation at this point may
result in loss of control and endanger the safety of the machine.
3. When the machine is on the flat bed of the step frame trailer any minor corrections to the
alignment can be corrected.
4. Always check your travelling height before starting your journey, and that the chains &
straps are secure.
Incorrect loading will result in uneven weight distribution through the axles and kingpin of your
lorry.

X38 Cone Crusher

X38 Cone Crusher
Section 3 Description and Technical Information
3.1 Application & Limitations
The X38 Cone Crusher has been designed and constructed to reduce minerals such as stone
and concrete to a predetermined size. The X38 Cone Crusher must not be used for any other
purpose without first contacting Extec Screens & Crushers Ltd technical department.
The X38 Cone Crusher must not be operated until the instructions supplied with the machine are
read and fully understood.
3.2 Description
The X38 Cone Crusher is a self contained tracked machine built to withstand the rigours and
conditions of operating in quarries and within the construction industry.
The X38 Cone Crusher utilises a diesel engine to provide the power to the hydraulic power pack
and to generate electricity for the electrical systems of the machine.
The tracks, feeders, cone, conveyors and all other working parts of the machine are hydraulically
driven.
Where possible all of the moving parts of this machine are guarded, where not, warnings are
provided. The Safety Section of this manual must be read and fully understood. Any residual
organisational, personal and environmental issues must be fully addressed as detailed in the
safety section.
This equipment has been manufactured and assessed to be in accordance with the Machinery
Directive 98/37/EC.
3.3 Operation Description
Section 2 and 4 of this manual provides details of Transport, Commissioning and Operation. This
must be read and fully understood before operating this equipment.
Material is loaded into the slew feeder where the conveyor transfers the material up towards the
opening of the cone, passing under a spreader plate on its way.
When the material reaches the top of the conveyor, it falls into the cones rock box, once there
the material is forced through the cone, crushing it as it goes.
After the material has passed through the cone it is transferred onto the main conveyor. The
material continues along the main conveyor where it is unloaded to a pile or to waiting transport.
Ver: BKX38-EN-00001 Description and Technical Information Page 33

X38 Cone Crusher
3.4 Key Features of the X38 Cone Crusher
• Diesel hydraulic power via Caterpillar C-13 Industrial C 440 bhp engine providing
hydraulic transmission without clutches.
• Telsmith 44SBS world leading cone.
• Variable speed, high torque for controlled and continuous feed.
• Hydraulic close side setting adjustment.
• Feed hopper mounted on hydraulically controlled slew ring, decreasing down time after
metal detection in feed material.
• Optional metal detector for feed hopper.
3.5 Common Applications
• Granite
• Slate
• Bricks
• Limestone
• Recycling/ Demolition
• Asphalt
This list is by no means exhaustive. Please contact Extec Screens & Crushers Ltd for further
details of performance figures and advice on your material.
Page 34 Description and Technical Information Ver: BKX38-EN-00001

X38 Cone Crusher
3.6 Machine Layout Indicating Main Components
FEEDER
TELSMITH 38SBS
POWER PACK CONVEYOR
CONE
MAIN CONVEYOR
ELECTRICAL
CONTROL BOX TRACKS
Figure 3-1: Main Components

X38 Cone Crusher
3.7 Machine Layout Indicating Emergency Stop Positions
Figure 3-2: Emergency Stop Positions
3.8 Data
Crusher
Feed Opening 865 mm (Diameter)
Crusher Speed 780 rpm
Drive Hydraulic
Lubrication tank 330 litres
Feeder
Hopper Capacity 2.8 cubic meters
Conveyors
Main Conveyor 800 x 8500 mm
Main Conveyor Speed 123 rpm

X38 Cone Crusher
Discharge Height 2.803
Dimensions
Transport Length 14742 mm
Transport Width 2741 mm
Transport Height 3431mm
Working Length 13749 mm
Working Width 3786 mm
Working Height 4488 mm
Weight 38 000 kg
Engine Details
Engine Caterpillar C-9 Industrial C 350 bhp
Engine Maximum Power 261 kW (350 bhp) @ 1900 rpm
Fuel Tank Capacity 390 litres
Hydraulic Tank Capacity 950 litres
Fuel Consumption Guide

100% Full load, continuous 67.8 litres/ hour
75% load 47.8 litres/ hour

X38 Cone Crusher
3.9 Machine Dimensions
Transport Width
2741m
Figure 3-3: X38 Cone Crusher Transport Dimensions
Figure 3-4: X38 Cone Crusher Working Area

X38 Cone Crusher
Section 4 Commissioning and Operation
4.1 Pre-Start Instructions
Before starting this machine it is important that the instructions below are followed:
1. Ensure that this manual is read and understood.
2. Do not attempt to start this machine until you are aware of all aspects of its operation.
3. Remove any temporary sealing and transport straps.
4. Check that the machine is in good mechanical condition and that there is no component
damage or loss.
5. Ensure that all bolts and fixings are tight and that all guards are in place with all safety
devices operating correctly. Never start this equipment without guards and safety
devices operating correctly.
6. Ensure that crusher chamber, feeder and conveyor belts are free of material.
7. Remove all tools and equipment from the operational area.
8. Ensure all personnel are well clear of the machine, drives, tracks and auxiliary
equipment.
9. Ensure that the pre-start checks outlined in the engine manufacturer's instruction manual
are complied with.
10. Check the oil levels in the engine, cone lubrication tank, cone adjuster gearbox, slew
feeder gearbox, hydraulic oil & feeder gearbox oil
11. Check that all drums and rollers turn freely. This must be done by hand. (Never attempt
to touch the drums or rollers whilst the machine is running.)
12. Ensure that the skirting rubbers and scrapers are in good condition and working properly.
Ver: BKX38-EN-00001 Commissioning and Operation Page 39

X38 Cone Crusher
4.2 Main Control Devices
4.2.1 Electrical Control Box
6 5 3
7 9 4 2 1
Figure 4-1: Electrical Control Box
1. Emergency Stop
2. Warning Lamp
3. Engine Speed Control
4. Diagnostic Lamp
5. Engine rpm Meter
6. Engine Warning Lights
7. Ignition Key (ON/OFF)
8. Soft Keys
9. Charge Warning Light
Page 40 Commissioning and Operation Ver: BKX38-EN-00001

X38 Cone Crusher
10 11 12 13 14 15 16 17 18
28
19 20 21 22 24 25 26 27
23
Figure 4-2: Electrical Control Box
10. Interlock (ON/OFF)

11. Recirculation Conveyor (ON/OFF)
12. Screen (ON/OFF)
13. Main Conveyor (ON/OFF)
14. Cone (ON/OFF)
15. Feeder (ON/OFF)
16. Spare
17. Track (ON/OFF)
18. Feeder (Extend/Retract)
19. Cone Adjust Panel Remote
20. Clamp ON
21. Manual Tramp
22. Size IN
23. Size OUT
24. Auto Feeder (ON/OFF)

X38 Cone Crusher
25. Calibrate Liner

26. Feeder Speed Down
27. Feeder Speed Up
28. Plug in Hard Wire Umbilical Socket.
4.2.2 Remote Control
Start Feeder
Stop Feeder
No Action
Remote Stop Engine
No Action
No Action
Sound Track Alarm whilst held
1: Remote Control
4.2.3 Engine Warning Lights
1 5
2 6
1. Water Temperature
3 7 2. Water and Fuel Sensor
3. Low Water Level
4 8 4. Emergency Stop Light
5. Engine On Light
6. Battery Light
7. Oil Light
8. Remote Control Emergency Stop
9. Ignition Switch Position
9
Figure 4-3: Engine Warning Lights

X38 Cone Crusher
4.3 Starting Procedure
2
1
3
Figure 4-4: Starting procedure
1. Turn on at main isolation switch (1) positioned in the hydraulic control box next to the
battery.
2. Set the speed control (2) to the No.1 position.
3. Turn the key (3) clockwise to the “ON” position. All lights will flash for several seconds.
4. Turn the key to the 'Start' position and hold until the engine starts.
5. Release key. Key will return to “ON” position.
6. Engine is now running at idling speed.
Note: The machine MUST be level in both longitudinal and traverse planes and set up on
firm level ground before being operated. Failure to comply with this or any other
instructions in this manual may cause damage to the machine and may invalidate
any warranty.
4.3.1 Cold Start
When starting the machine in temperatures of 0°C or below, run all systems at engine speed
No.1 for 15 minutes to allow the hydraulic oil to reach working temperature. DO NOT feed
material into machine during this time. When this is done stop all systems, turn engine speed
switch to No.2 and restart all systems. DO NOT turn engine speed switch from position 1 to 2
while any systems are running. DO NOT operate systems contrary to these instructions.
Caterpillar Engine: The ether starting aid is not equipped with an ether cylinder at the factory.
Before operating cold weather starting aid install 7N0296 Cylinder
Assembly.

X38 Cone Crusher
4.4 Stopping the Machine
To stop the machine, it is ESSENTIAL that the following steps be followed in order to prevent
damage to the machine:
1. Stop feeding material into the slew feeder.
2. Wait for all material to fully discharge from feeder, crusher chamber and conveyor belts.
3. Shut down systems in following order using the "stop" buttons in electrical control box:
a. Feeder
b. Crusher
c. Main conveyor
4. Wait for each system to come to a complete stop.
5. Turn engine speed switch to position No.1 and allow engine to idle briefly.
6. Stop engine by turning ignition key to 'OFF' position.

X38 Cone Crusher
4.5 Stopping Machine in an Emergency
THE MACHINE CAN BE STOPPED IN AN EMERGENCY BY PRESSING THE

EMERGENCY STOP BUTTONS LOCATED ON THE ELECTRICAL CONTROL PANEL
AND ALONG EACH SIDE OF THE MACHINE OR BY TURNING THE IGNITION KEY OR
ISOLATION SWITCH DIRECTLY TO 'OFF' POSITION.
ENSURE THAT ALL PERSONNEL IN THE VICINITY OF THE MACHINE ARE FULLY
AWARE OF THE LOCATION OF THE EMERGENCY STOPS.
4.5.1 Emergency Stop Locations
1: Emergency stop and ignition 2: Emergency stops on L/H &

switch in control box R/H jacking legs
3: Emergency stop on electrical

control box
Note: Emergency Stop switches should only be used in an emergency situation and not
for normal stopping. Frequent use will cause damage to the hydraulic components.
Note: Emergency Stop switches must be reset before the machine can be restarted.

X38 Cone Crusher
4.6 Preparing the Crusher for Operation
1: Raise main conveyor spray bar to working 2: Fix main conveyor spray bar in working
position. position and secure.
3: Unload ladder and hook into position.
4: Lift up rotating gate section, rotate & lower

into position. Repeat the procedure on other
side of machine. 5: Lower the railing into position. Repeat the
procedure on other side of machine.
Note: While operator is using the platforms
the safety gates MUST be closed.

X38 Cone Crusher
6: Lower rear jack legs by 7: Lower front jack legs by 8: Fit pins & R-clips to jack legs
operating levers. operating levers. (8 off).
10: Raise the side and back 11: Feeder Conveyor and doors
9: Raise the feeder conveyor.
feeder doors. in the raised position.
WARNING:
a. Ensure the machine is on a level surface before operating the jack leg levers.
b. Lift the machine uniformly.
13: Press button clamp on. This will enable the

12: Start the engine on speed No.1. See
“Starting Procedure” on page 43 lubrication circuit pump to start circulating the
oil through the cone.

X38 Cone Crusher
14: If the lubrication oil is below 15°C (59°F)

15: This will continue until the oil in the return
the oil pre-heat circuit will be enabled. This is a
pipe from the cone reaches 15°C (59°F) LT1 on
kidney type loop which pumps oil from the
the display panel. Once this temperature is
lubrication tank through a oil to water heat
reached this circuit will stop.
exchanger connected to the diesel engine.
Until the lubrication oil reaches the correct temperature, the cone is
disabled.
17: The cone lubrication circuit will have oil

16: Once temperature is reached turn to speed
flow of around 65 lpm (Lf on the display) with
No.2.
4-5 bar of oil pressure (Lp on the display).
19: For machines fitted with recirculation

18: Press the interlock on button. system, start the tail conveyor, screen box and
conveyors.

X38 Cone Crusher
21: Press the cone on button. (The cone is

20: Press the main conveyor on button disabled if lubrication flow is below 45 lpm and
pressure is below 1.5 bar.)
tracks on disables other hydraulic functions.
4.7 Operating The Machine (Crushing)
When the machine is set up as described in the previous pages, it is now ready to be operated.
To operate machine, turn engine speed to No.2 position and then start systems in the following
sequence:
1. Main conveyor
2. Cone crusher
3. Feeder
DO NOT START THESE SYSTEMS IF THEY ARE FULL OF MATERIAL. CLEAR ANY
MATERIAL AWAY BEFORE STARTING.
1: Turn engine speed switch to position No.2. 2: Start systems as per above sequence.
Prior to loading material into the machine, ensure that the machine is not vibrating or rocking
excessively. Stabilise with jacking legs if required, or relocate machine to more suitable ground.

X38 Cone Crusher
4.7.1 Loading Material Into Machine
1. Feeder MUST be running PRIOR to feed material being placed upon it. DO NOT start
feeder if it is full of material.
2. Material which is larger than 80% of feeder discharge chute should not be presented to
the feeder. STOP MACHINE and remove any large pieces of material with the
appropriate equipment. DO NOT use excavators to force any material into feeder as any
damage occurred from this action will invalidate any Extec Screens & Crushers Ltd
warrantees.
3. Material should be fed carefully, (not dropped onto feeder). Ensure that feeder is evenly
loaded.
4. It is recommended that the machine is fed from a screener/ jaw crusher or stockpiler
from a surge pile to keep an even flow of material at all times. DO NOT OVER FILL
HOPPER.
5. For maximum output and minimum wear, it is recommended that the crusher chamber is
fed consistently with the supply of material being steady and constant. STOP/ START
OPERATION OF THE FEEDER SHOULD BE AVOIDED.
6. Pressure switches are fitted to the crusher box side plate and should the crusher
chamber become overfilled for "X" minutes ("X" being adjustable to suit material) the
feeder will STOP until the material is reduced to an acceptable level. See Figure 1:
Adjusting feeder speed using control Panel. for adjusting feeder control speed. See
Figure 2: Starting/ Stopping feeder speed using remote control. for feeder cut-out switch.
2: Starting/ Stopping feeder speed using

1: Adjusting feeder speed using control Panel.
remote control.
When the machine is set up as described in the previous pages, it is now ready to be used to
crush the desired material. DO NOT START CRUSHING UNTIL YOU HAVE READ AND
FULLY UNDERSTOOD THIS MANUAL.

X38 Cone Crusher
4.7.2 Feeder Cut-out
The X44 Cone Crusher is fitted with a pressure sensing device that will cut out the operation of
the feeder when the pressure in the crusher chamber exceeds specified limits.
This reduces the chances of the crusher becoming blocked with material, as the machine will
have more time to deal with what is in the crusher chamber.
Once the pressure in the crusher chamber drops to within specified limits, the feeder will
automatically restart to give an uninterrupted crushing process. This system reduces the
chances of having to manually clear the crusher chamber and reduces the amount of down time.
1: Feeder cut out switch - on. 2: Feeder cut out switch - off.

X38 Cone Crusher
4.8 Feeding the Cone Crusher
1: Press the feeder on button. (The feeder is 2: Check all displays to ensure adequate oil flow
disabled until the cone is running.) and pressure are being maintained.
4: See “Oil System Operation and Maintenance”

3: See “ELECTRICAL INTERLOCK” on page 212
on page 217 of this manual regarding more
of this manual regarding interlock control of the
detailed information regarding the oil system &
cone.
service information.
1. Once the crusher is running, start to feed a steady stream of material into the feeder.
5: Control Panel
2. The feed of material can be regulated using the control panel situated in the hydraulic
control box.
3. For the optimum results the best way to feed the cone is with a screener or a crusher
with as much fines removed as possible.

X38 Cone Crusher
4.9 Setting Material Output Size
Figure 4-5: Control Panel
The X44 Cone Crusher has an adjustable discharge setting capacity. To set the size of the
output material, carry out the following procedure.
WARNING: The machine MUST be stationary and the crusher turned off whilst this
procedure is carried out.
Note: MACHINE MUST BE SHUT DOWN AND RESTARTED (Step 1 & 2) BEFORE JAW
CAN BE OPENED/ CLOSED.
Ign
itio
nK
ey
1: Stop the machine. Refer to “Stopping the 2: Restart the machine. Refer to “Starting
Machine” on page 44. Procedure” on page 43.

X38 Cone Crusher
3: Press button cone adjustment on. 4: Press button size in to close up cone.
5: Press button size out to increase CSS. 6: Lock jaw when adjustment is complete.
4.10 Using Remote Pendent For Setting Material Output Size

UT
EO
SIZ
P
STO
IN
ZE
SI
1: Turn to remote. 2: Remote pendent for opening jaw

X38 Cone Crusher
4.10.1 Setting Material Output Size
MODEL
57FC
MAXIMUM
FEED SIZE
FEED OPENING
C (OPEN SIDE)
FEED OPENING
(CLOSED SIDE)
B
A
MANTLE CONCAVE
RING
PARALLEL
ZONE
"D" DISCHARGE SETTING

(CLOSED SIDE)
Figure 4-6: Setting Material Output Size
Use suitable measuring equipment - ideally callipers - to measure distance between opposing
points on the concave and the mantle at minimum opening, known as closed size setting -
(CSS).
Measure jaw plates at opposing points as shown in the diagram.
Note: The crusher minimum CSS of the Cone will depend on the application and the
liners fitted to the individual machine.

X38 Cone Crusher
4.11 Access The Cone Crusher’s Data
F1 F2 F3 F4
1: At the electrical control box on the display
2: The home screen. Press F1 to return to this
use the Keys F1 to F4 to access the machine,
screen. (F2=Engine/Machine Hours)
engine and error data.
F1 F2 F3 F4 F1 F2 F3 F4
3: Press F4 to scroll through the home menu 4: Press F4 to scroll to the end. (F2=Error
options. (F2=Engine Data)(F3=Machine Data) Messages)
• Engine Data Information • Machine Data Information

Engine Hours, Coolant temperature/level, Oil Lubrication flow/temperature 1/temperature 2/
pressure, Boost pressure/temperature, Fuel pressure, CSS (Closed Size Setting), Choke,
rate/temperature/pressure, Load, Battery Feeder, Pump pressure, Conveyor Speed,
voltage and RPM. Clamp 1, Clamp 2, Prv type 2 and High
temperature.
4.12 Cone Crusher Motor Control Block Pressure Adjustment
SAFETY NOTICE
The following procedures are carried out with the machine running so extra care MUST be taken
to ensure the safety of ANY personnel on or in the vicinity of the machine.

X38 Cone Crusher
4.12.1 Start Up Pressure
ut
kN
int
L oc
Po
re
w
ssu
re
Sc
Pre
b
ru
G
1: Start Up Pressure 2: Adjusting Pressure
1. Attach pressure gauge to pressure point as shown.

2. Start crusher on speed on No.2 then stop crusher. The pressure gauge should read 350
bar. If required, adjust the pressure using following procedure.
3. Unscrew lock nut on relief valve grub screw. To reduce the pressure, turn the screw anti-
clockwise. To increase pressure, turn the screw clockwise. Turn screw about ¼ of a turn.
4. Repeat procedures 2 & 3 checking the pressure each time.
5. When the pressure reads 350 bar lock the screw in position with the attached lock nut.

X38 Cone Crusher
4.12.2 Brake Pressure
c re w
Lock u bS
N ut Gr
int
Po
re
su
es
Pr
M15 M4
1: Brake Pressure 2: Adjusting Pressure
1. Attach pressure gauge to pressure point as shown.

2. Start cone crusher at full speed on No.2 then stop cone crusher. The pressure gauge
should read 100 bar. If required, adjust the pressure using following procedure.
3. Unscrew lock nut on relief valve grub screw. To reduce the pressure, turn the screw anti-
clockwise. To increase pressure turn the screw clockwise. Turn screw about ¼ of a turn.
4. Repeat procedures 2 & 3 checking the pressure each time.
5. When the pressure reads 100 bar lock the screw in position with the attached lock nut.
Note: The rotor will run for at least 10 to 20 seconds after stopping the cone to allow for
smooth braking.
3: Return Pressure. For information only.

X38 Cone Crusher
Section 5 Machine Maintenance
5.1 Introduction
Maintenance is essential for safety and to ensure the best possible performance from your X38
Cone Crusher by reducing the chances of breakdowns.
WARNING: The machine MUST be switched off and isolated with the ignition keys removed
BEFORE making any adjustments.
DO NOT stand on any part of the engine whilst operating or carrying out any maintenance on
the machine.
All adjustments must ONLY be carried out by trained personnel. All adjustments to modify
hydraulic system must ONLY be carried out by trained Extec service engineers.
5.2 Daily Maintenance Schedule
Cap
Oil
1: Check engine oil level. 2: Refill if necessary.
(Refer to the engine manufacturer’s handbook for engine oil specification.)
Ver: BKX38-EN-00001 Machine Maintenance Page 59

X38 Cone Crusher
4: Refill diesel tank using the diesel pump and

3: Check fuel level. fuel suction pipe. Alternatively refill manually
after cleaning around the cap opening.
6: Check radiator water level & refill if

5: Bleed diesel water trap. necessary.
Use a 50/50 mixture of anti freeze and water.
5.2.1 Air Cleaner Servicing
Check the service indicators on the air cleaner. Regardless of the condition of the service
indicator, remove the primary air cleaner as shown below and clean, from the inside, using
compressed air. Only clean the primary filter a maximum of 6 times. Never clean the secondary
air cleaner. After 3 primary air cleaner replacements, replace the secondary air cleaner.
Page 60 Machine Maintenance Ver: BKX38-EN-00001

X38 Cone Crusher
Note: Service indicators are for showing when the air filter need to be replaced or cleaned.
Test the service indicator as laid out in the engine manufacturer's handbook.
1: Check the service indicator daily. 2: Unclip the cover and remove.
3: Remove and clean the primary air cleaner. The

4: Only remove and replace secondary air cleaner
primary air cleaner can be used up to six times if
after three services.
properly maintained. Replace at least once a year.
When the engine is operating in environments that are dusty or dirty, air
cleaner elements may require more frequent replacement.

X38 Cone Crusher
5: Cover the turbocharger air inlet in order to keep

6: Replace air cleaners and cover after cleaning.
dirt out. Clean the inside of the air cleaner cover
Reset the air cleaner service indicator.
and body with a clean, dry cloth.
For detailed cleaning instructions, refer to the instructions in the engine

manufacturer's handbook.
Filter Maintenance List
Part Number Description QTY
1. EN1003 AIR PRIMARY FILTER 1
2. EN1004 AIR SECONDARY FILTER 1
3. EN1008 INDICATOR-AIR FILTER CHANGE 1
5.3 Weekly Maintenance Schedule
Maintenance is essential for safety and to ensure the best possible performance from your X38
Cone Crusher by reducing the chances of breakdowns.
WARNING: The machine MUST be switched off and isolated with the ignition keys removed
BEFORE making any adjustments.
DO NOT stand on any part of the engine whilst operating or carrying out any maintenance on
the machine.
All adjustments must ONLY be carried out by trained personnel.
STOP MACHINE, ISOLATE AND REMOVE IGNITION KEY BEFORE

CARRYING OUT ANY MAINTENANCE ON THIS MACHINE.

X38 Cone Crusher
1. Check the condition of conveyor belts, rollers and other moving parts.
2. Clear any obstructions from the feeder conveyor and the cone’s rock box.
3. Check all bolts and panels are in place and secure.
4. Clear any build up of dust from the oil cooler and radiator using compressed air.
5. Check condition of service indicators on hydraulic filters, water trap and air breather.
Replace if necessary.
6. Check emergency stops are working correctly.
7. Grease bearings. See “Greasing Bearings”.
8. Inspect and adjust all belt scrapers and sealing rubbers if necessary.
5.3.1 Checking/ Changing Hydraulic Tank Air Breather
If the service indicator is green, it is time to

replace the tank air breather. Simply remove
air breather and replace with new one.
Note: If optional oil cooler is fitted, then it must
be in the raised position & cover plate
removed to access the air breather.
1: Raise cover plate and examine service

indicator.
5.3.2 Greasing Bearings
Extec Screens & Crushers Ltd use SKF sealed-for-life bearings that reduce grease
consumption, lower life cycle cost, lower recycling costs and reduce pressure on the
environment. The results are dramatically increased up-time for the machines and the
consequent reduction in maintenance costs. Only apply grease where otherwise indicated.
Follow maintenance instructions laid out in the engine manufacturer's handbook.
WARNING: NEVER USE GREASE CONTAINING MOLYBDENUM.

DOING SO MAY CAUSE DAMAGE TO MACHINE PARTS
AND WILL INVALIDATE ANY WARRANTY.

X38 Cone Crusher
See following pictograms for details of grease points and types.
1: Torque Arm motor bearings 2: Torque Arm shaft bearings
Torque Arm
X38 Cone Bearings
See manufacturer's handbook. 50 grams/ 40 hours
Grease LGHQ3/18
Track Gear Boxes Feeser Conveyor Bearing

Fill to Oil Levels Grease EP2
EP90 Gear Oil
Figure 5-1: Grease Points

X38 Cone Crusher
5.3.3 Inspecting/ Adjusting Belt Sealing Rubbers
1: Sealing rubber in correct

2: Adjust as required. 3: Refit clamp fixing screws.
position & condition
5.3.4 Adjusting Belt Scraper
If required, adjust head drum scraper by

loosening bolts in Rosta springs, adjusting
scraper and re-tightening bolts.
Both sides should be adjusted simultaneously.
1: Adjusting Belt Scraper
5.3.5 Hydraulic Filter
Check service indicators on hydraulic filters when the machine is running. CHECKING
CONDITION OF FILTER INDICATORS IS THE ONLY CHECK TO BE MADE WHEN MACHINE
IS RUNNING. STOP MACHINE BEFORE REPLACING ELEMENTS.
1: Lift up cover & inspect service indicator. 2: Replace elements if service indicator is red.

X38 Cone Crusher
Note: If optional oil cooler is fitted,

please refer to next page for
maintenance instructions for
hydraulic filters.
3: Replace cap, ensuring O-ring is in place. 4: Close and secure cover plate.
5.3.6 Changing Hydraulic Water Trap
Note: When the water trap is taken

off, oil will spill out. Use a
suitable container to catch
any waste oil - expect
between 3 and 5 litres.
Replace water trap as
shown.
1: Replacing hydraulic water trap.
CLEAN UP ANY OIL SPILLS AFTER PERFORMING THESE

OPERATIONS.
5.4 250 Hour Maintenance Schedule
Every 250 hours, the following maintenance must be carried out to ensure the best performance
and least possible amount of downtime from your machine.
1. Follow maintenance instructions laid out in the engine manufacturer’s handbook.
2. Change the hydraulic water trap regardless of condition of service indicator.
3. Change the hydraulic tank air breather regardless of condition of service indicator.

X38 Cone Crusher
4. Flush hydraulic system and change the hydraulic filters regardless of condition of
service indicator. To flush hydraulic system, proceed as follows:
a. Ensure all material has passed through the crusher and off the conveyor belts.
b. Stop the machine and replace the hydraulic filters with 3 micron flushing filters
(EN1405).
c. Fit new 10 micron water trap.
d. Check condition of hydraulic tank air breather. If the service indicator is red,
change it. Otherwise clean all dust from the base of the filter.
e. Run all systems for 4 hours with engine speed set to No.1 position. (DO NOT
FEED MATERIAL INTO THE MACHINE DURING THIS OPERATION.)
f. Stop machine and replace flushing filters with new 25 micron hydraulic filters.
5. Check for leaks on hydraulic pipes.
6. Inspect condition of conveyor belts and tracking.
7. Inspect condition of all drums and rollers.
8. Check drive belts for wear, swelling, softening and tension. Replace if necessary.
Note: Tension should remain constant during the belts working life and should not be re-
tensioned.
9. Clean out sediment bowl on fuel pre-filter.
Note: When sediment bowl is cleaned out, the fuel system will have to be re-primed.
Proceed as follows:
2: Unscrew hand primer and pump until a

steady flow of fuel comes out of filter. (No
1: Loosen bleed screw on fuel filter. bubbles must be coming through fuel line.) Re-
secure hand primer after use. Re-tighten bleed
screw.
5.5 1000 Hour Maintenance Schedule
Every 1000 hours, the following maintenance must be carried out:

X38 Cone Crusher
1. Repeat 250 hour maintenance schedule.

2. Change diesel filters.
3. Change oil in tracks.
5.5.1 Changing Oil in Tracks
To drain oil from the track gearbox, drive the machine until the oil drain plug is at the bottom of
the gearbox. Remove both plugs and the oil will drain out. Use a suitable container to collect
waste oil. Replace drain plug.
Disposing of waste oil must be done in a manner that complies with

current environmental legislation.
To refill track gearbox with oil, drive the machine until the gearbox is in the correct position. See
below.
Note: This will only be 1/3 turn of the track gearbox.
DO NOT drive machine any further until oil has been replaced in tracks. Remove the oil
level plug as shown in the photographs below. Fill with oil into the oil level plug until it
starts to come out of the plug hole. Replace oil level plug BEFORE driving the machine.
Each track gearbox will have to be maintained separately.
TOP
OIL FILL
LEVEL
OIL DRAIN
1: Track gearbox in correct position to refill with oil.

X38 Cone Crusher
When changing oil in the tracks, use Exol

M10 Ethena EP90 Gear Oil.
2: Remove oil level plug.
5.6 Track Adjustment
WARNING!
Grease under pressure can cause serious injury. Never unscrew a track
adjuster valve by more than a ½ turn, when the track is under tension.
After maintenance or over time the track will become slack and will have to be adjusted. The
adjustment of the tracks operates through a tensioning cylinder (C). When the cylinder is filled
with grease it extends and pushes the spring tension unit (B), and the idler (A), forward. The
grease is filled through the track adjuster grease valve (D).
B
1: Track Adjustment
In order to establish if the track requires tensioning, move the Host machine a few metres
forwards and backwards on level ground. This allows the tracks to adopt their natural degree of
tension.
Using a straight edge and a measuring tape, measure the droop of the track group as shown at
(E). For this particular track set, the droop should not exceed 30 mm.

X38 Cone Crusher
Note: It is also important that the track is not tensioned too tightly as this places excessive
loads on the gearbox and idler bearings. It will also lead to accelerated wear and
premature failures.
30 mm (Max)
E
2: Track Adjustment Settings
5.6.1 Increasing The Track Tension
To increase the tension of the track:

1. Remove the inspection cover on the side of the track frame as shown at (F).
2. Ensure that the track adjuster valve (H), is tight.
3. Attach the special grease gun connector (G), to a grease gun and fit it onto the track
adjuster valve (H).
4. Pump grease into the valve until the droop of the track is correct.
5. Move the Host machine backwards and forwards a few times more and then re-check
the droop. Add more grease if required.
6. Check for any escaping grease around the tensioning unit and finally close the
inspection cover when finished.

X38 Cone Crusher
Important: Ensure that the correct grease is used.
3: Increasing The Track Tension
5.6.2 Releasing The Track Tension
To the release the tension on the tracks:

1. Remove the inspection cover on the side of the track frame as shown at (F).
2. Loosen the track adjuster valve (H), by turning it one half turn anticlockwise.
3. Grease should now escape slowly from the track tensioning cylinder and the track should
slacken.
4. If the track fails to loosen, apply a little pressure to the idler end of the track to push the
idler group in.

X38 Cone Crusher
5. Replace the inspection cover when completed.
4: Releasing The Track Tension
5.7 Oils And Fluids
Lub/ Oil and Grease Manufacturers Equivalent

Temperature Viscosity
Points Specifications
Anti Freeze Shell Safe Anti Freeze Concentrate
Cone Lubricating Oil Shell Omala HD 150
Warm Weather Shell Omala HD 220*
Diesel Shell Agricultural Gas Oil
Engine Oil Shell Rimula Signia 10W-40
Cold Weather Shell Diesel Engine Oil Rimula 5W-

30
Engine Oil - Alternative See Manufacturer’s Handbook
Hydraulic System ISO VG 32 Shell Tellus Arctic 32
ISO VG 46 Shell Tellus 46
ISO VG 68 Shell Tellus Oil 68
ISO VG 100 Shell Tellus Oil 100
Environmentally Shell Naturelle HF-E 46

friendly
General Lubrication Shell Albida EP2

Points
Arctic Shell Aeroshell 33

X38 Cone Crusher
Lub/ Oil and Grease Manufacturers Equivalent

Temperature Viscosity
Points Specifications
Torque Arm Bearings Exxon Unirex N 3 Grease (LGHQ3)
Tracks Exol Ethena EP90 Gear Oil
Tracks - Alternative Shell SPIRAX GSX75W-80
* Please contact Extec Screen & Crushers Ltd Technical Department before using this oil.
A full list of Substances Hazardous to Health associated with this equipment can be found in the
appendix of this document.
5.8 Crusher Fault Codes
Code Fault
C0001-00 ESTOP
C0002-00 Remote Stop activated by handset
C0003-00 Communication problem - Engine interface unit not receiving messages from rest of crusher
electronics
C0004-00 Communication problem - Engine interface unit not receiving messages from CAT engine
C0005-00 Communication problem - Crusher electronics is not receiving any messages from 32way
receiver
C0006-00 Communication problem - Crusher electronics is not receiving any messages from analog
sensor box
C0007-00
C0008-00 Communication problem - Crusher electronics is not receiving any messages from daisy
chain box
C0009-00 Communication problem - Crusher electronics is not receiving any messages from track led
box
C0010-00 Communication problem - Crusher electronics is not receivng any messages from motorised
valve unit
C0011-00
C0012-00
C0013-00
C0014-00
C0015-00 Crusher electronics is performing SKF vibration analysis test (duration 60 seconds)
C0016-00 Crusher electronics is seeing a problem with switch matrix, stuck button / shorted wires
C0017-00 C12+ Trying to start jaw but receiving bent toggle plate signal, check toggle plate switch

X38 Cone Crusher
Code Fault
C0018-00 Crusher electronics has picked up excessive vibration during test. Shutdown crusher and
check bearing
C0019-00 Crusher electronics is destroking hydraulic pump to relieve excess pressure.
C0020-00 Crusher electronics has stopped crusher unit due to excessive pressure, pump already
destroked.
C0021-00 C12+ crusher electronics is picking up low grease signal from vogel unit.
C0022-00
C0023-00 Motorised valve unit is not connected to motor
C0024-00 Motorised valve unit is not seeing motor turning, possibly jammed motor, faulty wiring.
C0025-00 Electrical problem with CCB output0, dependent on machine:
C0032-00 Electrical problem with CCB output7, dependent on machine:Engine Stop
C0033-00 Electrical problem with Receiver output0, dependent on machine:PCO,L2, Purple
C0034-00 Electrical problem with Receiver output1, dependent on machine:
C0035-00 Electrical problem with Receiver output2, dependent on machine:Manual Tramp, R3, Green/
Yellow
C0036-00 Electrical problem with Receiver output3, dependent on machine:Lube Oil Cooler, Brown
C0037-00 Electrical problem with Receiver output4, dependent on machine:Accumulator Hold, R1,
Blue/White
C0038-00 Electrical problem with Receiver output5, dependent on machine:Lube Pump, Slate
C0039-00 Electrical problem with Receiver output6, dependent on machine:Clamp Ring Release (not
hosed), L3, Blue
C0040-00 Electrical problem with Receiver output7, dependent on machine:Lube Pre Heat, Blue
C0041-00 Electrical problem with Receiver output8, dependent on machine:Accumulator Hold, L1,
Brown
C0042-00 Electrical problem with Receiver output9, dependent on machine:Screen Box, No Tape, 2
C0043-00 Electrical problem with Receiver output10, dependent on machine:Main Converyor, Red
Tape, 4
C0044-00 Electrical problem with Receiver output11, dependent on machine:Recirc Converyor, White
Tape, 5

X38 Cone Crusher
Code Fault
C0045-00 Electrical problem with Receiver output12, dependent on machine:Feeder, Brown Tape, 1
C0047-00 Electrical problem with Receiver output14, dependent on machine:Cone Drive, Green Tape,
8
C0049-00 Electrical problem with Receiver output16, dependent on machine:Tracking valve, destroke
pump,
C0051-00 Electrical problem with Receiver output18, dependent on machine:Cone gap adjust, R5,
Orange
C0052-00 Electrical problem with Receiver output19, dependent on machine:Slew feeder, L5, Yellow
C0053-00 Electrical problem with Receiver output20, dependent on machine:Cone gap adjust, R6,
White/Red
C0054-00 Electrical problem with Receiver output21, dependent on machine:Slew feeder, L6, Pink
C0055-00 Electrical problem with Receiver output22, dependent on machine:Clamp main cylinders,
R4, Blue/Yellow
C0056-00 Electrical problem with Receiver output23, dependent on machine:Locking ring clamp, L4,
Slate
C0058-00 Electrical problem with Receiver output25, dependent on machine:Lube Oil Cooler2
C0059-00 Electrical problem with Receiver output26, dependent on machine:Main Conveyor lift, Yellow
tape, 14
C0060-00 Electrical problem with Receiver output27, dependent on machine:Main Conveyor lower,
Blue tape, 15
C0061-00 Electrical problem with Receiver output28, dependent on machine:Left track forward, 10
C0062-00 Electrical problem with Receiver output29, dependent on machine:Right track forward, 12
C0063-00 Electrical problem with Receiver output30, dependent on machine:Left track reverse, 11
C0064-00 Electrical problem with Receiver output31, dependent on machine:Right track reverse 13

X38 Cone Crusher

X38 Cone Crusher
Section 6 Trouble Shooting Guide
Below is a list of some of the common problems that might occur on your machine. If these
problems arise, carry out the checks listed.
PROBLEM SOLUTION
Engine losing power or hard to Check air filter isn’t blocked.
start. Check diesel filter and sediment bowl.
Engine won't start or keeps Check that emergency stops are not pushed in.
shutting off. Check water level in radiator.
Check fuel level.
Check that the batteries are charged and that the
terminals are tight.
Check oil pressure, temperature, battery and over-speed
warning lights on electrical control panel.
Cone crusher won't start. Check that cone button is on in electrical box.
Check lube temp gauge. Minimum 15°C.
Check lube pressure gauge. Minimum 1.5 bar.
Check lube flow gauge. Must be above 45 lpm.
Check fuel level.
Check hydraulic oil level in tank.
Check that there are no hydraulic pipes leaking.
Check flywheel belt tension.
Check engine speed switch is at No.2 position.
Clean air filter, diesel filter & diesel sediment bowl.
Flywheel slowing under load. Check hydraulic oil level in tank.
Check that there are no hydraulic pipes leaking.
Check flywheel belt tension.
Check engine speed switch is at No.2 position.
Clean air filter, diesel filter & diesel sediment bowl.
Slew conveyor not working. Check Webtec is fully open.
Machine "Rocking" excessively. Check flywheel alignment.
Check ground conditions are firm and level.
Check tracks are not slack. If they are see 5.6.1
Increasing The Track Tension on page 70.
Ver: BKX38-EN-00001 Trouble Shooting Guide Page 77

X38 Cone Crusher
PROBLEM SOLUTION
Machine not tracking. Check oil level in the hydraulic tank.
Check that interlock and track buttons are on.
Check remote handset is fully charged. Plug in Hard Wire
Drive and try to move machine.
Check that all levers are in their central position and
check if the crusher operates. If cone crusher operates
and levers are central but the machine still won't track,
this may indicate an electrical problem. Contact Extec
Screens & Crushers Ltd immediately.
Main or Slew Conveyor belts Check belt tension.
jammed. Ensure that there is no build-up of material underneath
machine.
Clean under machine as shown in following photographs
as required.
1: Using jacking legs, lift the machine off 2: Ensure that locking pins and R-clips are fitted
ground. BEFORE cleaning below the machine.
6.1 Test Procedures for Electronics
Symptoms:
Engine is shutting down and remote stop lamp on EPU is showing.
The crusher electronics shuts down the engine via the EPU for 3 reasons:
1. Signal received by receiver from correctly coded handset requesting “fast stop”.
2. Red button on override handset has been pressed.
3. Crusher control box has lost communications with the receiver unit.
Page 78 Trouble Shooting Guide Ver: BKX38-EN-00001

X38 Cone Crusher
To identify which of the above cases is correct please look at the lamps above the interlock on
switch, the interlock off switch and the lamp above the jaw remote switch.
Case 1)
Receiver believes it is receiving a signal from a handset. Lamp state as follows:
Lamp above jaw remote switch: Flashing
Lamp above interlock off switch: Lit
Lamp above interlock on switch: Dark
Before the crusher shuts down, the green lamp on the track LED box should flash briefly to
indicate signal being received from handset.
Check:
All handsets are switched off. If necessary remove batteries from small handset.
Case 2)
Override handset used. Lamp state as follows:
Lamp above jaw remote switch: Flashing
Lamp above interlock off switch: Dark
Lamp above interlock on switch: Dark
Check:
Unplug manual handset, check back of socket for manual handset for dirt/ water contamination
or damage to wiring.
Case 3)
Lost communications. The crusher control box (unit with 36 way connector inside switch box) is
having problems communicating with the receiver unit. Lamp state as follows:
Lamp above jaw remote switch: Lit
Lamp above interlock off switch: Flashing
Lamp above interlock on switch: Flashing
Check:
• Receiver is switched on, red lamp should flash whilst crusher is still running, will change
to constantly illuminated when crusher shuts down.
• Track lamps run through start up test, this test is actually performed by the receiver, if the
track lamps perform test then the receiver is communicating correctly with the track
lamps box.

X38 Cone Crusher
• Check 6 way connector near the receiver; all wires are matched up with the correct
colour wire on both sides of the receiver. Connector is plugged in securely and all wires
are secure in the crimp contacts.
• Check yellow and white wires inside switch box are securely fitted to screw terminals.
• Check yellow and white wires from screw terminal inside switch box to 36 way connector
on crusher control box. White wire should go to bottom row, end contact on the right of
the connector as you look into the switch box. The yellow wire is on the same row to the
left of this. The important point is that the white wire is on the end contact and the yellow
is one contact in. Check these wires to ensure they are not swapped or poorly crimped.
6.2 Checking Hydraulic Pressure
3: Check tank return pressure 5: Check suction pressure using

4: Check control pressure using a
using a 0 - 10 bar pressure a 0 - 6 bar pressure gauge - this
0 - 100 bar pressure gauge. This
gauge - this should be not should be between ½ bar min.
should be 40 bar at all times.
greater than 4 bar. and 1½ bar max.
6.3 Checking 5 Station Manifold Pressure
(Where applicabla.)
Check pressure at test points shown to check the feeder, magnet, side and main conveyor using
a 0 - 250 bar pressure gauge. Pressure readings when running empty should be:
4. Side conveyor - 30 bar. Peak pressure - 200 bar.
5. Feeder (Cold start) - 100 bar - this should drop to 50 bar when warm. Peak pressure -
200 bar.
6. Feeder pan - 50 bar. Peak pressure - 200 bar.
7. Main conveyor - 50 bar. Peak pressure - 240 bar.
8. Magnet - 30 bar. Peak pressure - 200 bar.

X38 Cone Crusher
1 2 3 4 5
Figure 6-1: Test points are on manifold block on

side of valve plate.
IF ANY PROBLEM PERSISTS AFTER CARRYING OUT THE RECOMMENDED SOLUTION,

OR A PROBLEM ARISES THAT IS NOT ON THIS LIST, CONTACT Extec Screens & Crushers
Ltd SERVICE DEPARTMENT FOR FURTHER ASSISTANCE.
ADJUSTING PRESSURE SETTINGS OR REFILLING HYDRAULIC OIL ON THE MACHINE

SHOULD ONLY BE CARIED OUT BY TRAINED Extec Screens & Crushers Ltd SERVICE
ENGINEERS.

X38 Cone Crusher

X38 Cone Crusher
OEM Manuals supplied with this

machine
Title- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Issue No Date

1. CATERPILLAR C-9 Operation and Maintenance Manual - - - - - - - - - - - - - - - -
2. C-9 Industrial Engine Parts Manual CD - - - - - - - - - - - - - - - - - - - - - - - - - - - -
3. ERIEZ METALARM MA300 SERIES METAL DETECTORIOM-MA-3000 REV A
4. Siemens SITRANS Probe LU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5. Extec X38 Operation and Maintenance Manual - - - - - - - - - - - - - - - - - - - - - - -
6. Wear Liner Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
(If sonar is fitted)
7. XRS-5 ECHOMAX Operations Manual - - - - - - - - - - - - - - - - - - - October 2005
8. HYDRORANGER 200 Instruction Manual - - - - - - - - - - - - - - - - - January 2006
Ver: BKX38-EN-00001 Appendix C Page 177

X38 Cone Crusher
Page 178 Appendix C Ver: BKX38-EN-00001

X38 Cone Crusher
Eriez Metalarm MA300 Series Metal Detector

MA3000
E R I E Z M E T A L A R M
MA3000 SERIES
METAL DETECTOR
Description of Installation and Operation
SERIAL NUMBER:
CHECKED BY:
DATE:
DOCUMENT No: IOM-MA-3000

REVISION: A
ERIEZ MAGNETICS EUROPE LIMITED

BEDWAS HOUSE INDUSTRIAL ESTATE BEDWAS CAERPHILLY CF83 8YG
UNITED KINGDOM TEL. +44 (0) 2920 868501 FAX. +44 (0) 2920 851314
ERIEZ METALARM PAGE 1
Ver: BKX38-EN-00001 Eriez Metalarm MA300 Series Metal Detector Page 179
X38 Cone Crusher
MA3000
Table of Contents
1.0 INTRODUCTION
2.0 INSTALLATION
2.1 Control Unit Mounting
2.2 Search coil Mounting
2.2.1 Underbelt TR Coil (Flat Pack)
2.2.2 TR10 Coil
2.2.3 Bridge Coil
2.2.4 U section belt conveyors or vibrator conveyors
2.2.5 Plate Coil
3.0 ELECTRICAL CONNECTIONS

3.1 Power Supply
3.2 Sensor Coil Connections
3.3 Control Relay Contacts
3.4 Fuse
4.0 OPERATING INSTRUCTIONS

4.1 Indicator Lights
4.2 Sensitivity Adjustment
4.3 Signal Level Indicator
4.4 Electronic Board Mounted Switches
5.0 ELECTRONIC CIRCUIT BOARD REPLACEMENT
6.0 WIRING TO THE CONVEYOR MOTOR CONTACTOR
7.0 AUXILIARY RELAY

7.1 Auxiliary Relay Wiring
8.0 EARTHING OF ASSOCIATED EQUIPMENT WHEN FREQUENCY INVERTER SPEED CONTROLS ARE
BEING USED
9.0 SUGGESTIONS FOR TROUBLE SHOOTING ENVIRONMENTAL INTERFERENCE

9.1 Movement of Metal
9.2 Intermittent Loops of metal surrounding the sensor
9.3 Excessive line voltage fluctuations
9.4 Proximity of severe RF radiation source
10.0 PARTS LIST
11.0 TECHNICAL DATA
Page 180 Eriez Metalarm MA300 Series Metal Detector Ver: BKX38-EN-00001
X38 Cone Crusher
MA3000
METALARM 3000 CE
1.0 INTRODUCTION
The METALARM (MA) 3000 Metal Detector, consists of a control unit, one or more sensor coils
dependent upon the application and optional accessories such as the sack dropper.
The optional QUARRYMASTER version of the control unit is constructed from stainless steel and is fitted
with an anti condensation heater & thermostat for frost protection. The thermostat is normally set to
+5°C.
These instructions are concerned with the installation and operation of the control unit, sensor coils
and accessories.
Figure 1
X38 Cone Crusher
MA3000
2.0 INSTALLATION
2.1 Control Unit Mounting
The MA3000 control unit is supplied with HDPE (high density polyurethane) mounting brackets for wall
mounting. Dimensions are shown in the diagram, Figure 1.
Ideally the control unit should be mounted within 3-5 metres of the sensor coil unit and no more than
20 metres.
The MA3000 control unit will normally be mounted by means of four M8 or 5/16 inch bolts utilizing the
four mounting holes.
Adequate clearance must be allowed below the control unit enclosure to allow for cable entry and
exit.
On no account must the HDPE mounting brackets be replaced, as these are provided to electrically
isolate the control unit from the metal conveyor framework. Similarly no metal work should be in
contact with the metal control unit case after mounting on the conveyor.
Failure to comply with the above mounting procedures will invalidate the 'CE' certificate covering
the EMC regulations.
2.2 Search Coil Mounting
The following instructions give details of how to install the various types of standard search coils
supplied as part of the Metalarm Metal Detector.
2.2.1 Underbelt TR (Flatpack) Coil - Idler Conveyors (figure 2)
A) Locate a suitable position in the conveyor mid way between two idler sets where:
1. There will not be a return idler or cross piece beneath the search coil.
2. There is no join in the conveyor frame
3. Metal when detected can easily be removed from the conveyor belt
4. There is no moving metal in the vicinity
5. Where any metal base plate present can be removed or replaced by non metallic material.
6. Where any metal over-belt covers can be removed or replaced
B) Place the search coil on the conveyor frame at the chosen position. There should be at least a
25mm (1 inch) gap between the underneath of the (fully loaded) conveyor belt and the top
of the search coil. If not cut out notches in the bottom of the search coil at all four corners so
as to lower the search coil within the conveyor frame.
C) Brackets to hold the search coil to the conveyor frame (not supplied) should be fitted to the
coil to secure it to the conveyor stringers.
D) The search coil should then be bolted to the conveyor frame so that the coil socket is on the
opposite side of the conveyor frame to any heavy duty cables.
E) The idlers either side of the search coil should be checked to see that all nuts and bolts have
been tightened down. Ideally the idler frames should also be spot welded once at each of
the four corners to the conveyor frame.
X38 Cone Crusher
MA3000
The cable to connect the search coil to the control unit should then be plugged into the
underneath of the search coil and run back to the control unit. The cable should be tied down so it
does not get damaged.
SENSOR COIL PLATES
SIDE SUPPORT PLATES

CO-AX CABLE TO
METALARM CONTROL
UNIT SMALL ANGLE BRACKETS
(NOT SUPPLIED) CONVEYOR STRINGER
Figure 2
2.2.2 TR10 Type Search Coil – Idler Conveyors (figure 2A)
Follow the instructions as listed in section 2.2.1 points A-E for the coil location & installation.
This type of coil configuration is designed for transmit/receive mode operation only and both coils
are connected directly to the control unit. See section 3.2 (sensor coil connections) and figure 2A
below. Remember in both cases to make sure the cables are tied to the conveyor frame to prevent
them being damaged.
RECEIVER COIL
TRANSMITTER COIL
LL ANGLE BRACKETS
T SUPPLIED) SIDE SUPPORT PLATES
CENTRE SUPPORT PLATE
CONVEYOR STRINGER
Figure 2A
X38 Cone Crusher
MA3000
2.2.3 Bridge Type Search Coil - Idler Conveyors (figure 2B)

A) Locate a suitable position in the conveyor mid way between two idler sets where:
1. There will not be a return idler or cross piece beneath the search coil.
2. There is not a join in the conveyor frame
3. Metal when detected can easily be removed from the conveyor belt
4. There is no moving metal in the vicinity
5. Where any metal base plate present can be removed or replaced by non metallic material.
6. Where any metal over-belt covers can be removed or replaced.
B) Assemble the lower coil on the side supports & place on the conveyor frame at the chosen
position. There should be at least a 25mm (1 inch) gap between the underneath of the (fully
loaded) conveyor belt and the top of the search coil. If not cut out notches in the bottom of
the search coil at all four corners so as to lower the search coil within the conveyor frame.
C) Brackets to hold the search coil to the conveyor frame (not supplied) should be fitted to the coil
to secure it to the conveyor stringers.
D) The search coil should be mounted on the conveyor frame so that the coil socket is on the
opposite side of the conveyor frame to any heavy duty cables.
E) Fit top search coil section and bolt down
F) The idlers either side of the search coil should be checked to see that all nuts and bolts have
been tightened down. Ideally the idler frames should also be spot welded once at each of the
four corners to the conveyor frame.
In the case of series connection, connect the lower coil using the short length of cable provided
using the unmarked socket on the top coil. The cable to connect the search coil to the control unit
should then be plugged into the socket marked ‘CU’ on the top search coil and run back to the
control unit. See 3.2
In the case of transmit/receive mode operation; both coils are connected direct to the control unit.
See 3.2. Remember, in both cases make sure the cables are tied to the conveyor frame to prevent
them being damaged.
RECEIVER COIL
SMALL ANGLE BRACKETS

(NOT SUPPLIED) SIDE SUPPORT PLATES
TRANSMITTER COIL
CONVEYOR STRINGER
Figure 2B
X38 Cone Crusher
MA3000
2.2.4 “U” Section belt conveyors or vibrator conveyors - Search coils (figure 3/4)
A) Locate a suitable position in the conveyor where there is going to be no metal within 500mm of
the underneath of the search coil when it is mounted onto the conveyor. Simultaneously there
is no moving metal in close proximity to the search coil. In the case of vibrator conveyor the coil
is usually located midway between two of the vertical supports.
B) To install a trough coil, it is necessary to cut out a length of the base and part of the side walls of
the conveyor. The dimensions of the required cut out can be found by measuring the recessed
area of the search coil.
COUNTERSINK FROM INNER

SURFACES OF TROUGH
DRILL MOUNTING HOLES
ALONG THIS PATH
REMOVE SECTION FROM

TROUGH
SECTION VIEW CUT OUT LENGTH
RECESSED AREA
SENSOR COIL
CUT OUT HEIGHT
Figure 3
C) Draw a line 25mm from the edge of the cut out. Along this line drill M8 holes at 100mm (4 inches)
spacing or longer depending upon the weight and width of the search coil. Countersink the
holes from inside the conveyor.
D) Locate the search coil into the cut out and clamp into position. Then using the trough as a
template spot mark through the holes from the inside of the trough directly onto the coil.
E) Fix the search coil into position using countersunk M8 bolts x 40mm long, shakeproof washers,
and nuts.
X38 Cone Crusher
MA3000
F) The cable to connect the search coil to the control unit should then be plugged into the
underneath of the search coil and run back to the control unit. The cable should be tied down
so it does not get damaged.
UNDERSIDE VIEW
CO-AX CABLE TO
METALARM CONTROL
UNIT
M8 FIXINGS
Figure 4
X38 Cone Crusher
MA3000
2.2.5 Plate Coil (figure 5)
Plate coils can either be mounted beneath a pre-prepared metal free section such as wood or
fiberglass, or providing the plate coil is an SF or SFC type directly onto the base of a metal sided
conveyor.
In the latter case if the base of the conveyor is metal this must be removed for the length of the coil
plus 3mm.
The search coil can be drilled into or through in any of the crossed areas shown below as long as it is
a minimum of 25mm away from the coil windings.
SECTION VIEW
SENSOR COIL
CONVEYOR STRINGER
CONVEYOR BELT
SENSOR COIL
DRILL
FRONT VIEW
COIL WINDINGS
Figure 5
X38 Cone Crusher
MA3000
3.0 ELECTRICAL CONNECTIONS - (See Figure 6.)
The standard electrical connections are for power supply connections and for sensor coil
connections. Other cables may be added as necessary for control and monitoring functions.
Please note where armoured cables are being used, the armouring must be cut back at the gland
plate of the control unit such that it does not touch the Metal Detector Control Unit, as this will
compromise the electrical isolation of the Control Unit.
This also applies to electrical trunking.
230
OPTIONAL FAULT
RELAY CONNECTION
TB2
TB1 TB3 TB4

1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 1 2 3 4
EXT FAULT INPUT (+5VDC)
DC PSU INPUT
E E N N L L N/C C N/O N/C C N/O N/C C N/O N/C C N/O

C C
MAINS POWER DETECT RELAY

POWER LIGHT
RESET SWITCH
DETECT LIGHT
2 1
SENSOR COILS
SW4 POSITION
1: SINGLE COIL CONNECTION (TX)
2: SECOND COIL CONNECTION (RX)
AUXILIARY TERMINAL
Figure 6
3.1 Power Supply
The mains connection is made via the terminal block TB1 using 'E' for earth/ground connection,
either of the 'L' terminals for live 1/positive connection and either of the 'N' terminals for live 2/neutral
connection.
The spare 'L', ‘N’ and 'E' terminals can be used for driving external controls or the bag dropper
accessory for example.
The Voltage Selector Switch should be set to 230VAC or 115VAC as required. This is located just
above the connector TB1.
DIN RAIL TERMINAL
OPTIONAL: If the system has been requested to operate BLOCK
from a DC voltage, the input voltage must be within the
range 18-30VDC.
The input supply should be applied to the DIN rail terminal
block mounted in the bottom of the control unit at the
1
terminals listed below. (-)

2
2 – NEGATIVE SUPPLY (0V – GREEN/YELLOW)

3
5 – POSITIVE SUPPLY (FUSED TERMINAL)

4
NOTE The DIN rail terminals are not fitted in the standard LINE LOAD
5
(+)
mains (AC) powered units.
X38 Cone Crusher
MA3000
3.2 Sensor Coil Connections
The sensor coil connection is made via the right hand 4 way terminal block TB4. When only one coil
is used, or a Bridge coil is being used with coils in series, connect to terminals 3 & 4.
The inner conductor is connected to terminal 'C' and the outer braiding to terminal
For applications where two coil windings are being used and there are two coil cables, i.e. separate
transmitter and receiver coils; the search coil with the coil socket marked ‘RX’ should be connected
to TB4 1 and 2 and the search coil with coil socket marked ‘TX’ should be connected to TB4 3 and 4.
Note: Switch 4 should be moved to position 2, when in transmitter/receiver mode (TX/RX).
3.3 Control Relay Contacts
Connection to the output contacts of the control relay are made to terminal block (TB2) as
indicated in drawing Figure 6. Four sets of SPDT relay contacts are provided.
In the instance of the optional FAULT relay being fitted, then terminals 10, 11 & 12 of TB2 are used for
this signal. This leaves three sets of SPDT relay contacts for the DETECT signal on TB2 (terminals 1-9).
Note that the FAULT relay operates in a ‘fail-safe’ mode – so when power is applied to the control
unit, it will change state.
The contacts are rated for 5 amps resistive, for either low voltage DC application or for a maximum
of 250V ac application.
3.4 Fuse
Please note there is only one fuse on this Control Unit, located on the front panel and rated at
500mA (230VAC) or 1A (115VAC) A/S.
4.0 OPERATING INSTRUCTIONS - (See Figure 7.)
E E N N L L
Figure 7
Switch on the line power and the 'ON' lamp on the case door illuminates.
The red 'FAULT' light will be on if the sensor coil is not connected. When the sensor is properly
connected the light will extinguish.
X38 Cone Crusher
MA3000
Note: The illuminated fault light will also cause the 'Detect' lamp to be on.
Rotate the SET ZERO control fully clockwise. If the right hand light illuminates, rotate the Set Zero
control anti-clockwise until this light extinguishes and the green light illuminates.
This adjustment compensates or zeros out any near by metal in the sensor coil detect area. If this
light cannot be illuminated there may be too much metal near the sensor coil. This can be
confirmed by positioning the sensor coil away from all surrounding metal and repeating the test.
After these adjustments, the detector may have operated illuminating the 'Detect' light and the
'Reset' lamp on the detector door. Pressing the 'Reset' lamp button will extinguish both lights.
The ‘Relay’ switch controls the relay function. In the OFF position only the 'Detect light and door
'Reset' lamp operate when metal is present in the sensing area.
In the ON position, the 4 pole DPDT relay, the 'Detect' light and the door 'Reset' lamp operate when
metal is present in the sensing area.
In the LATCH position, the relay and above indicators operate but after the metal is removed, the
relay and the indicators remain on until either the door 'Reset' button is pressed or the 'Relay' switch
is turned to the ON or OFF position.
The 'Sensitivity' control is a gain adjustment control to adjust for the detection of the desired size of
material or to allow for smaller pieces of material to be ignored.
4.1 Indicator Lights
SET ZERO
When the Metalarm is operating and correctly set, the green light of these three lights is the only one
illuminated.
If a piece of metal passing across the Sense coil is large enough it will cause the green light to go
out and the right hand red light to come on while the metal is within the detect range of the Sense
coil.
DETECT
This red light illuminates whenever metal is within the detect range of the Metalarm.
COIL FAULT
This red light illuminates if the sensor is either open circuit, not connected or short circuited.
This light also causes the Detect light to illuminate to prevent operation of the Metalarm until the coil
fault is rectified.
Normally, the Metalarm control unit should not require any major re-adjustments after performing
the adjustments during installation. After switching the control unit on, the green 'Set Zero' light
should illuminate immediately without the need to turn the 'Set Zero' control. Proper operation may
be verified by depressing the 'Test' button, which is mounted on the electronic circuit board
beneath the front panel.
Certain extremely large objects may produce an overload signal causing the unit to indicate
continuously even after the object has passed clear of the sensor coil. Depress the 'Reset' button to
cancel the indication.
NOTE:
Although the control unit will adequately zero out stationary masses of background metal, it will
respond to moving metal near the sensor coil. When mounting the sensor coil, consideration should
not be limited to only large objects such as fork lift trucks, but should be extended to smaller objects
such as maintenance workers carrying metal tools and equipment in the vicinity.
Although the metal detector system is suppressed against both airborne and power supply
interference, some false alarms may nevertheless occur occasionally. Such triggering is usually due
to transient effects, which are both infrequent and unpredictable.
Metallic framework encircling the search coil can act as a "shorted turn". It may be necessary to
insert insulating sections to prevent comparatively small masses of metal generating inordinately
large background signals.
X38 Cone Crusher
MA3000
4.2 Sensitivity Adjustment
The 'Sensitivity' controls permit sensitivity adjustments for detecting or rejecting the desired size of
objects. Rotate the 'Sensitivity' control clockwise to increase the Metalarm sensitivity or counter-
clockwise to decrease the sensitivity.
A coarse sensitivity adjustment (VR1) may be performed by means of the sensitivity adjustment
control on the control unit printed circuit board (see figure 8). Extreme care must be used in
performing the coarse sensitivity adjustment. Consult the factory prior to making any coarse
sensitivity adjustments.
NOTE:
Take particular care, as with the mains supply connected parts of the printed circuit board will be
carrying high voltages. Therefore DO NOT touch anything other than the coarse sensitivity control
you are adjusting.
Rotating the coarse sensitivity adjustment control in the clockwise direction may reduce the
sensitivity of the control unit. Rotate this control one section at a time, checking each time to
determine whether the gain has been reduced sufficiently.
After each coarse sensitivity adjustment, it may be necessary to rezero the internal lights using the
'Set Zero' control and depress the reset button on the enclosure door.
4.3 Signal Level Indicator
This consists of a row of ten LED’s, which light in sequence from left to right, as the detected signal
level increases when metal approaches the sensor. Normally none or perhaps the first 1 or 2 LED’s
on the left side may be flicking ON and OFF and the last LED on the right side will be constantly ON.
Upon detection of metal each LED starting from the left will individually illuminate until the last two
LED’s on the right hand side are ON. This will mean that metal has been detected and the LED’s will
then revert back to the normal position (stated previously). However, if the Metalarm is suffering
from 'false alarms' which are of a fairly regular nature, then this indicator should be examined, since
it may show more than the first one or two indicators flickering ON and OFF indicating the presence
of some interference which is either mains or airborne. Rotating VR10 clockwise may reduce the
effects of this. The signal level should now move to the left until only 1 or 2 indicators are on. Care
should be taken to not rotate this control further than necessary, since it does reduce the sensitivity
of the unit.
The setting for this control can be measured with a voltmeter between test points TP0 and TP19. The
default value is 180mV.
X38 Cone Crusher
MA3000
4.4 Electronic Board - Mounted switches - (See Figure 8.)
SW1
Figure 8
For the position of the switches, which control additional optional features, refer to figure 8 above.
SW1 Selection of voltage - 115V or 230V 50Hz or 60Hz AC
SW2 (1) Brown - This prevents the metal detector being reset when metal is still in the field of the
search coil - Can only be used when the conveyor belt stops immediately after metal is
detected - to ensure all metal has been removed before the conveyor belt can be
restarted.
(2) Red -Fail Safe Operation. - This powers up the 'Detect' relay immediately power is
connected to the control unit rather than when metal is detected. When metal is detected
therefore the 'Detect' relay drops out. Similarly if power to the unit fails the relay also drops
out - creating a fail safe mode.
All controls on SW2 are off in the 'up' position and 'on' when in the down position.
SW4 This separates the TX and RX coil connections when switched to position 2 and is used when
separate search coils are used for transmitting and receiving, such as to create an even
search field or where magnetic ores are being processed.
SW5 Test button.
SW6 This, when switched 'on', i.e. in the ‘up’ position, reduces the integrator speed. This facility is
used where belt speeds are slow, such as in the Wood Industry and where noise levels are
high.
5.0 ELECTRONIC CIRCUIT BOARD REPLACEMENT
Normally, access to the electronics is not required but if the circuit board requires replacement, the
following procedures must be used.
Turn off the mains supply to the control unit and disconnect all terminal blocks connected to the
base of circuit board by pulling downwards.
Undo the three panel fixing clips by turning a 1/4 turn anti-clockwise.
Undo the five screws holding the two mounting brackets and remove.
Undo the five pillars and three mounting screws. Remove the circuit board and inspect the
enclosure. Remove any foreign material such as loose pieces of metal filings or wire cutting etc.
Install the new circuit board in the reverse procedure of above. Refer to section 4 for testing and
operation.
X38 Cone Crusher
MA3000
6.0 WIRING TO THE CONVEYOR MOTOR CONTACTOR
To stop the conveyor drive motor when metal is detected, connect the Metalarm normally-closed
relay contacts (terminals C and N/C on (TB2)) in series with the conveyor motor contactor, KM1, as in
Figure 9.
After removing the metal, if the system is wired as shown in Fig 9, the conveyor will not restart until
the Metalarm control unit is reset AND the conveyor motor start switch is depressed.
230
TB2
TB1
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12
E E N L N/C C N/O N/C C N/O N/C C N/O
STOP START KM1 SAFETY STOP
KM1
L1
L2 M
L3
KM1
Figure 9
Note: If the metal detector is operated in ‘fail-safe’ mode, then the wire connected to pin 1 of TB2
should be moved to pin 3, as the relay will change polarity when power is applied to the control
unit.
X38 Cone Crusher
MA3000
7.0 AUXILIARY RELAY
An auxiliary relay is necessary between the Metalarm Control Unit and the motor starter when the
motor wiring system is a fully three-phase delta with no star-point and uses a motor starter with a
415V coil.
The 415 volt motor starter coil exceeds the maximum voltage rating of the Metalarm output
contacts, which are rated at 250V ac maximum.
An auxiliary relay or small contactor is required for the 415V ac contacts.
An auxiliary relay is also necessary when the plant switchgear is generating electrical interference or
brushes are arcing, or when other electrical noise is being created.
This interference will propagate through the air and may also travel along the conductors in close
proximity to the noise sources. When this occurs, interference will be fed into the Metalarm Control
Unit along the interconnecting wires, and will cause false triggering.
An auxiliary relay in a separate enclosure, external to the Metalarm and separate from the main
switchgear cabinet, will normally isolate the offending interference.
7.1 Auxiliary Relay Wiring
230
TB2
TB1
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12
E E N L N/C C N/O N/C C N/O N/C C N/O
RL1
RL1
Auxiliary Relay Wiring Diagram
Note: If the metal detector is operated in ‘fail-safe’ mode, then the wire connected to pin 1 of TB2
should be moved to pin 3, as the relay will change polarity when power is applied to the control
unit.
X38 Cone Crusher
MA3000
8.0 EARTHING OF ASSOCIATED PLANT WHEN FREQUENCY INVERTER SPEED CONTROLS ARE BEING
USED.
Please note that when frequency inverter speed controls are being used in the vicinity of the metal
detector all earth connections must be run independently back to a single star point as shown
below:-
In addition, if filters are being used they should be mounted and connected as shown below:-
INSTALLATION RECOMMENDATIONS FOR CONNECTING

RFI FILTERS TO HIGH FREQUENCY INVERTER DRIVES
Because of the complex circuit design used in these filters an Earth Leakage Current of 8 to 80mA
may be observed. It is possible that nuisance tripping of extremely sensitive type of ELCBs may
occur so this figure should be considered when choosing such a device.
It is important to provide well defined paths for the high frequency currents involved so, by far the
best results are achieved when both filter and inverter are mounted securely on the same
conducting, earthed backplate and not on rails etc.
Supply Cable
The supply cable should be a stranded conductor and not a solid conductor type to achieve
proper connection inside the terminal block, also cable lengths inside the wiring cabinet should be
kept to a minimum i.e. cable entry to filter and filter to inverter. This will reduce the effect of
radiated emissions back into the input cables.
X38 Cone Crusher
MA3000
Motor Cable
Since the cable between the inverter and motor is a major source of radiated and conducted
interference, it should be a screened type and as short as possible with the screen and safety earth
core connected directly to the bonded earth post at one end and to the motor earth at the other.
Never connect only one end of the screen to earth as this can be detrimental. (Pig tail effect). It is
strongly recommended that the conducting cores (not the earth or screen) are threaded through,
or, if possible, wound around an output cable filter choke as shown.
Earthing
The point here is to clearly define the paths through which high frequency earth currents flow, and
thereby minimise their harmful effect on other nearby, sensitive devices. All earthing leads, including
filter earth, inverter earth and screened cable earths, should be as short as possible and securely
fastened to the bonded backboard earth post - poor connections and loops of cable will act as
aerials and pick up stray radiated emissions.
Separation
Keep the separation of the input and output cables as great as possible to prevent feedback. Input
and motor output cables should never be run together in the same trunking or conduit.
Control Cables
The control cables to the inverter or any other equipment in the vicinity are obviously highly
susceptible to radiated emissions in the same way and should also never be run along side motor
output cables.
Multiple Inverters
Where more than one inverter is used, for effective suppression, it is preferable that a separate filter
should be used for each inverter.
X38 Cone Crusher
MA3000
9.0 SUGGESTIONS FOR TROUBLE SHOOTING ENVIRONMENTAL INTERFERENCE
The Metalarm Control Unit generates a high frequency alternating field within and near the sensor
coil. While the field is strongest on the sensor coil face or in the throat of the sensor coil, it is inherent
in the sensor coil design that a certain amount of the field exists outside of the sensor coil. Certain
environmental conditions may sometimes affect this alternating field causing false and erratic
signals.
If after installation the unit does not work properly, check for compliance with the following hook-up
and installation details before proceeding to the specific causes of interference.
All cable connections should be tight on the terminal blocks in the control unit. Any sensor coil lead
splice should be soldered and taped.
The power source cables should be isolated from varying inductive loads and should be run in a
separate conduit.
The control unit should have a good electrical ground connection.
In certain locations more than one problem may exist and the problems may be interrelated.
Observing the installation site and the operation of the metal detector for repeating symptoms is
very helpful in isolating the causes of the problems.
Correlating malfunctioning occurrences is invaluable for environmental interference trouble
shooting. Observe whether interference occurs at certain specific times and in conjunction with
specific activity.
Observe whether interference occurs when operated by certain personnel or only after physical
change of the environment.
Use the following to help diagnose problems and problem sources and to implement corrective
measures.
Basically environmental interference may be classified into four types, as described below:
9.1 Movement of Metal
Large masses of metal such as shaker screens, metal deflection plates, vehicles etc. may affect
metal detector operation even when at a considerable distance from the sensor coil.
Other smaller masses of moving metal when sufficiently close to the search unit may also cause false
trips.
Interference may exist outside of the room or building and be hidden from operators view, such as
vehicular traffic in an alley next to the building wall or a chain conveyor below or above the floor, or
moving metal objects in an adjacent room.
Corrective Measures
x Secure moving metal objects or remove them altogether if possible, or replace with a non
metallic material. Re-route vehicular traffic.
x Place a metal shield securely fastened and stationary between the sensor and the source of
interference. Place a shield as close to moving object as possible. The size of the shield will
depend on the size of the moving object.
x Install the metal detector in another location free from interference sources.
9.2 Intermittent loops of metal surrounding the sensor (Shorted Turns)
A source of interference, which is difficult to recognise, is that of the shorted turn. A shorted turn is
formed by metal pieces forming a complete path in an orientation around or near the sensor.
If this is intermittent, as in the case of two pieces of conduit occasionally touching together, the
detector will trip each time the conduits make or break connections. The intermittence may be
caused by physical deflection or vibration of equipment, and by expansion or contraction of metal
due to temperature changes.
X38 Cone Crusher
MA3000
The effect of the 'shorted turn' is that of a secondary 'coil' or 'turn' coupled to the metal detector
sensor coil. The varying load of this secondary 'coil' when it makes or breaks is reflected to the sensor
coil tripping the control unit.
The following metal objects may be part of or form a 'shorted turn' by themselves: metal framework,
pipes, conduit, flexible conduit, guard railing, metal catwalks, conveyor rolls, etc.
To determine the existence of a 'shorted turn’: switch the metal detector off and disconnect the
sensor lead at the terminal block. This will disconnect the sensor from the control instrument and
there will be no metal detection.
Now, turn the control instrument on again and set gain control to maximum. Run operation under
normal conditions and observe the signal level indicator. If the indicator is stable at this time, it is
most likely that the sensor is picking up a ‘shorted turn’. However, the problem may also be a break
on the sensor cable.
Check for breaks at this time and replace the cable if necessary.
If the cable is in good condition search for a 'shorted turn' as described in the following paragraph. If
the level indicator is not stable at this time, the problem is likely to be due to excessive line voltage
fluctuation.
To isolate and correct the 'shorted turn' problem, reconnect the sensor coil and turn off all
surrounding equipment in order to eliminate any vibration.
The level indicator should settle down at this time or at least reduce the number of false trips.
Proceed by tapping on all metal objects, starting near the sensor coil and working out from there, in
order to find where the break point is located. It is suggested that one person watch the level
indicator on the control unit in order to observe any movement while another person is tapping on
metal objects around and near the sensor coil.
In some cases, this may be several feet from the sensor coil. Sudden level indication movement
when a metal object is tapped will indicate the intermittent connection. It may be possible to fix the
problem by insulating or permanently securing this metal to metal connection. For example, in the
case of broken weld, re-weld or in the case of a loose pipe or conduit, re-secure the holders.
9.3 Excessive Line Voltage Fluctuations
Electrical interference may be in the form of line voltage 'spikes' caused on-off varying inductive
loads of electrical equipment on the same power line as the metal detector, or other power lines in
close proximity to the supply line for the metal detector.
Corrective Measures
x Use another power line, (without the varying inductive loads) for the metal detector.
x Disconnect electrical equipment causing the large inductive loads.
x Connect interfering electrical equipment to another power source.
x Re-route the power line to the metal detector.
x Install a constant voltage transformer (120 va. minimum) between metal detector and power
source.
9.4 Proximity of Severe RF Radiation Sources
Electrical or electronic interference can be radiated into the sensor coil or introduced into the metal
detector from other energy emitting devices such as arcing motors, arc welders, and arcing relay
points.
Corrective Measures
x Remove or replace equipment causing interference.
x Operate welding equipment only at times when metal detector is not required to operate.
Call the factory service department if unable to arrive at a satisfactory solution. Telephone: + 44 (0)
2920 868501 email: eriez@eriezeurope.co.uk
X38 Cone Crusher
MA3000
10.0 MA3000 CE Case Assembly Parts List
1/2
10
3/8
4/8
Ref No Description Qty

01 Case fully fitted 1
02 Enclosure 400x300x150 (SS or painted steel) 1
03 Indicator Assembly (POWER). 1
04 Momentary Illuminated Switch Assembly (DETECT/RESET). 1
05 Front Door Wiring Loom 1
06 Insulated Mounting Kit 1
07 Cable Gland PG11 Brass - As req'd
08 Filament bulb MBC 2
09 Label 1
10 Door Key 1
SEARCH COIL CABLES
Cable Search Coil - 1m 1

X38 Cone Crusher
MA3000
MA3000 CE Electronic Assembly Parts List
21
24
25/27
22
23
29
28 25/26
31
30
33 32
Ref No Description Qty
** Electronic Unit Complete 1
21 PTL147A Printed Circuit Board 1
22 Front Panel MA3000 CE 1
23 Push Latch Arrow 2001 3
24 Bargraph Module with plug 1
25 Control knob 3
26 Plain cap for control knob 1
27 Pointer cap for control knob 2
28 Relay 4PCO 1
29 Fuse T500mA/1A 20mm 1
30 Plug 4 way 1
31 Plug 6 way 1
32 Plug 9 way 1
33 Plug 12 way 1
** Electronic unit comprises - printed circuit board, bargraph module, front panel etc. all mounted on
back plate
X38 Cone Crusher
MA3000
11.0 TECHNICAL DATA
POWER SUPPLY 115 – 230VAC VIA SELECTOR SWITCH 50/60Hz

(24VDC VERSION AVAILABLE ON REQUEST 2A STARTUP CURRENT CAPACITY REQUIRED)
POWER 11W
FUSE 1A – 500mA (115/230)
RELAY 4PCO VOLT FREE
250V/5A MAXIMUM RATING
TEMPERATURE 0 TO +50°C
MATERIALS CONTROL UNIT: POWDER COATED STEEL OR STAINLESS STEEL
SENSOR COIL: HDPE (HIGH DENSITY POLYETHYLENE)
SENSOR CABLE RG58/URM76 50 OHM CO-AXIAL CABLE
IP RATING IP66 (NEMA 4X)
X38 Cone Crusher
X38 Cone Crusher
Default settings for MA3000 24v when shipped from Eriez.

Settings & Connections for Front panel.
1. Sensitivity control set to Max
2. Relay control set to Latch position.
3. Adjust Zero control for Green LED on. When coil & power are connected.
4. Earth Terminal marked with Earth symbol on back plate = 0v DC / Gnd. input.
5. Fused input terminal marked with +V symbol on back plate = +24v DC, (1A 5 x 20mm Fuse (T)).
6. TB4 – 3, Screen on Coil Cable (Earth ID symbol used).
7. TB4 – 4, Core of Coil Cable (“C” ID symbol used).
Settings for PCB as shipped from Eriez. (Front Panel removed).

1. SW2 Brown section up.
2. SW2 Red section up. Power fail-safe mode NOT selected.
3. SW4 Arrow pointing to 1 for single coil operation.
4. SW6 Down (Off position as indicated on switch body).
5. VR10 – Trip level set to 180mV +/- 5mV. (measure across TP0 = 0v & TP19 = 180mV r5mV)
Common Faults & Remedies for MA3000 24v.

Detect & Fault LED on indicates a coil or coil cable problem
1. Coil Cable broken / cut.
2. Coil connector socket faulty on coil.
3. Coil plug solder joints could have failed.
4. Coil plug not inserted correctly.
5. Coil connections to TB4 missing.
6. Coil connections to TB4 incorrect – High erratic signal “noise” on display.
To check coil & coil cable, unplug socket part of TB4 from front panel and with a Volt Meter set to resistance, place probes across socket
terminals of TB4.Using TB4,3 & TB4,4.
Results are –
1. Open circuit, see 1 to 4 above. Try new coil cable
2. Reading of 1K5: r 2 : (ohms) – possible coil winding open circuit.
3. Check connections inside cable socket on coil. If Ok a new coil is needed.
4. Reading of 2 – 10 : (ohms) – Coil windings Ok. (Depending on coil type & size).
5. If all above Ok possible failure of MA3000 contact Eriez for further help & advice.
Alarm output active but no detect or fault LED’s on.
To carry out quick tests on MA3000, remove front panel, turn relay control switch to “On” and press SW5. This activates the MA3000 for as
long as the switch is pressed. Don’t forget to switch relay control back to latch mode when testing is finished.
For the length of time SW5 is pressed the following happens. The relay de-energises, The detect LED light comes on, The door
lamp indicator comes on, The zero balance right hand red LED comes on and a trip signal is seen on the bar-graph display.
1. LED & switch lamp indication could have failed. check the following –
1a – If MA3000 resets, check wiring from TB3 to switches / lamps.
1b – Check reset lamp is Ok.
1c – Check for +12v dc across TB3. TB3,8 = 0v & TB3,9 = +12v dc. Voltage should only be present when MA3000 is in detect or
SW5 is pressed.
2. Check Red position of SW2. SW2 should be in the down position. MA3000 is in power fail-safe mode.
3. Relay not operating. Remove relay and see if external alarm condition is cancelled. If alarm condition still present – 3a – Check
external wiring from TB2 and ensure that all connections are correct.
X38 Cone Crusher
MA3000 will not reset.
1. MA3000 detect LED is ON but fault LED is OFF. MA3000 won’t reset from door switch, check the following –
1a – Check reset switch is able to operate freely. Switch is not clogged up with dust etc.
1b – Check for +3 to 5v dc across reset switch terminals 3 & 4 and TB3,6 – 0V & TB3,7 – +ve.
1c – If voltage present remove blue wire from reset switch terminal and touch it to the white wire terminal. If reset condition clears,
check reset switch contactor & replace if necessary.
1d – Momentary short TB3,6 & TB3,7, If reset condition clears check wiring from TB3 to reset switch.
1e – Switch Relay control switch to Off position. Detect status should clear. Depending on the trip / fault condition. The detect signal
might not go out until the reset switch has been pressed as well.
1d – If still unable to clear detect with reset switch or above suggestions contact Eriez for further help & advice.
TP5 Fault LED Detect LED TP19

+5v DC TP2
TP3 +12v DC
+12v DC #VR10
Trip level
TP1 adjust
+20 to 25v DC This LED
Trip Level should be on
measurement mV
TP4 VR9
+12v DC PTL147A Issue 3
Sensitivity Adjust
To Test Points
TP1, TP2 etc TP16
TP0 SW5
0v DC Test Button
On
Off
SW6
Decay Curve
TP11
DVM + 0 ŷ
SW3
0v +v
Off On Latch
VR5
FS1 TP7
Coil Zero Tx Pulse
Frequency
Relay
TP6
Frequency Measure
SW2
115
Default setting
240
Fail Safe
Red Section 1 2
Relay Operation Mode #VR1 SW4
Brown Section Frequency & Coil Selector Position = 1
Not Used (up position) Sample Delay
setting
TB1 TB2 TB3 TB4
# VR1 & VR10 are factory set, do not adjust unless requested to do so by Eriez.
X38 Cone Crusher
MetAlarm Voltage Levels Check Sheet

Fault LED Detect LED TP19
TP5 TP2
+12v DC
TP3
VR10
TP1 Trip level
adjust
This LED should
Trip Level meas- be on
TP4 VR9
+12v DC PTL147A Issue 3
Sensitivity Adjust
To Test Points
TP1, TP2 etc
TP0 SW5
0v DC Test Button
On
Off
SW6
Decay Curve
TP11
DVM + 0 ŷ
SW3
0v +v
Off On Latch # VR2
Tx Frequency set
VR5
FS1 TP7
Coil Zero Tx Pulse
Frequency
Relay
TP6
SW2 Frequency Measure
115
Default setting Position
240 1 = 1 coil
Fail Safe 2 = 2 coils
Red Section 1 2
Relay operation mode. # VR1 SW4
Frequency & Coil Selector
Brown section Sample Delay
# VR3
Not used, must be left setting
Decay curve dampening
TB1 TB2 TB3 TB4
# VR1 & VR10 are factory set, do not adjust unless requested to do so by Eriez.
Test Point Voltage on Test points Measured Result
TP0 0v, GND etc
TP0 - TP1 +20 to + 25v DC +/- 2v
TP0 - TP2 +12v DC +/- 500mV
TP0 - TP3 -5v DC +/- 300mV
TP0 - TP4 +12v DC +/- 500mV
TP0 -TP5 +5v DC +/- 300mV
Trip Level = TP0 – TP19 Factory set 190mV +/- 15mV
X38 Cone Crusher
MetAlarm Coil & Coil Cable Testing

TB4
Rx Tx
Coil Coil
TB1 TB2 TB3

C C
1 2 3 4
Check coil cable connections
Cable marked “C” for core.

Cable marked with for Gnd
Unplug Cable socket from TB3
Place meter probes across one set of coil

cables, as shown below
DVM
Resistance meter
Com R
Normal coil resistance reading is between 2 - 8 ohms,

depending on coil type and size.
If reading <1 ohm or S / C (short circuit) check coil ca-

ble for damage.
If reading in Mega ohms, OL or O / P (open circuit)

check coil cable has not been cut or unplugged from
detector coil socket.
If Meter reads 1.5 K ohms then the detector coil has

failed and a new coil will be required.
X38 Cone Crusher
MetAlarm Coil Cable Testing & Binder Disassembly
Cable tail
Binder Plug
Earth / Screen Coil Cable
To To
TB4 Coil
“C”
Core
Coil cable is connected as follows.
“C” / Core is connected to pin 1 in the binder plug
Earth / screen is connected to pin 2 in the binder.
From “C” to pin 1 the resistance should be 0 ohms (0) or SC (short circuit).
From Earth to pin 2 the resistance should be 0 ohms (0) or SC (short circuit).
From “C” to Earth the resistance should be infinity ( ) or OP (open circuit).
Disassembly of Binder plug is as follows
Check solder joints are clean, free of any contamination and are DRY.
Ensure joints have good contact and Ok.
Binder Plug, Pin Locations
Front View Rear View
Coil cable is connected as follows.

2 1 “C” / Core is connected to pin 1 in the binder plug 1 2
Earth / screen is connected to pin 2 in the binder.
X38 Cone Crusher
X38 Cone Crusher
Siemens SITRANS Probe LU
Quick Start Manual November 2005
sitrans
PROBE LU (HART)
Ver: BKX38-EN-00001 Siemens SITRANS Probe LU Page 209

X38 Cone Crusher
SITRANS Probe LU
7ML1234-78910-ABC-D Encl.: NEMA/TYPE 4X, 6, IP67, IP68
Serial No: GYZ / S1034567 Amb.Temp.: – 40°C to 80°C
Power Rating: 24V Nom., 30V Max., 4-20 mA
Siemens Milltronics Process Instruments Inc., Peterborough
Made in Canada
Refer to drawing: 23650516 Ui = 30 V, II 1G

Class I, Div 1. Group A, B, C, D Ii = 120 mA,
EEx ia IIC T4
Class II, Div 1, Group E, F, G Pi = 0.8 W
Class III Ci = 3.6 nF, SIRA 03ATEX2142X
Li = 0
HART
WARNING: Possible static hazard, do not rub or clean on site.
Page 210 Ver: BKX38-EN-00001

X38 Cone Crusher
SITRANS Probe LU Quick Start Manual

This manual outlines the essential features and functions of SITRANS Probe LU. We strongly
English
advise you to acquire the detailed version of the manual so you can use your instrument to its
fullest potential. The complete manual is available on our website at:
https://pia.khe.siemens.com/index.asp?Nr=11157. The printed manual is available from your
local Siemens Milltronics representative.
Questions about the contents of this manual can be directed to:
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: techpubs.smpi@siemens.com
Copyright Siemens Milltronics
Process Instruments Inc. 2005. Disclaimer of Liability
All Rights Reserved
We encourage users to purchase While we have verified the contents of this manual
authorized bound manuals, or to view for agreement with the instrumentation described,
electronic versions as designed and variations remain possible. Thus we cannot
authored by Siemens Milltronics Process guarantee full agreement. The contents of this
Instruments Inc. Siemens Milltronics manual are regularly reviewed and corrections are
Process Instruments Inc. will not be included in subsequent editions. We welcome all
responsible for the contents of partial or suggestions for improvement.
whole reproductions of either bound or
electronic versions. Technical data subject to change.
MILLTRONICS is a registered trademark of Siemens Milltronics Process Instruments Inc.
Safety Guidelines1
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied by
a clarification of the level of caution to be observed.
WARNING: relates to a caution symbol on the product, and means that failure to
observe the necessary precautions can result in death, serious injury, and/or
considerable material damage.
WARNING1: means that failure to observe the necessary precautions can result
in death, serious injury, and/or considerable material damage.
Note: means important information about the product or that part of the operating manual.
1. This warning symbol is used when there is no corresponding caution symbol on the product.
7ML19985QR81 SITRANS Probe LU (HART) – QUICK START MANUAL Page EN-1
Ver: BKX38-EN-00001 Page 211

X38 Cone Crusher
SITRANS Probe LU
English
WARNING: Changes or modifications not expressly approved by Siemens

Milltronics could void the user’s authority to operate the equipment.
Note: SITRANS Probe LU is to be used only in the manner outlined in this manual,
otherwise protection provided by the equipment may be impaired.
SITRANS Probe LU is a loop-powered continuous level monitor, using advanced ultrasonic

techniques. The unit consists of an electronic component coupled to the transducer and
process connection.
The transducer is available in ETFE (ethylene-tetrafluoroethylene) or PVDF (polyvinylidene
fluoride), allowing SITRANS Probe LU to be used in a wide variety of industries and
applications using corrosive chemicals.
The ultrasonic transducer contains a temperature sensing element to compensate for
temperature changes in the application.
Communication is via HART1, and signals are processed using Sonic Intelligence®.
Specifications
For a complete listing, see the SITRANS Probe LU Instruction Manual. For Approvals
information, please refer to the device nameplate.
Ambient/Operating Temperature
Note: Process temperature and pressure capabilities are dependent upon information
on the product nameplate. The reference drawing listed on the nameplate can be
downloaded from the Siemens Milltronics website. Go to the product page at:
https://pia.khe.siemens.com/index.asp?Nr=11157.
hand programmer
product nameplate
ambient temperature
surrounding enclosure: flange adaptor
–40 to +80 °C (–40 to +176 °F)
customer-
supplied flange
process temperature:
–40 to +85 °C (–40 to +185 °F)
1. HART® is a registered trademark of the HART Communication Foundation.
Page EN-2 SITRANS Probe LU (HART) – QUICK START MANUAL 7ML19985QR81

X38 Cone Crusher
Power
Nominal 24 V DC at max. 550 Ohm: for other configurations see the full manual.
• Maximum 30 V DC
English
• 4 to 20 mA
Approvals
• General: CSAUS/C, FM, CE
• Hazardous: Intrinsically Safe (Europe) ATEX II 1 G EEx ia IIC T4
(US/Canada) FM/CSA: (barrier required)1
Class I, Div. 1, Groups A, B, C, D
Class II, Div. 1, Groups E, F, G
Class III T4
(Australia) ANZEx Ex ia IIC T4
(Tamb = –40 to +80 °C) IP67, IP68)
(International) IECEx TSA 04.0020X Ex ia IIC T4
Non-incendive (US) FM: 2
Class I, Div. 2, Groups A, B, C, D T5
• Marine Lloyd’s Register of Shipping

ABS Type Approval
Note: The use of approved watertight conduit hubs/glands is required for Type 4X /
NEMA 4X, Type 6 / NEMA 6, IP67, IP68 (outdoor applications).
1.
See FM Intrinsically safe connection drawing on page 1 of Appendix A, for reference drawing
23650516, or CSA Intrinsically Safe connection drawing on page 2 of Appendix A, for reference
drawing 23650517.
2. See FM Class 1, Div. 2 connection drawing on page 3 of Appendix A, for reference drawing 23650583.

X38 Cone Crusher
Installation
WARNINGS:
English
• Materials of construction are chosen based on their chemical compatibility (or

inertness) for general purposes. For exposure to specific environments, check with
chemical compatibility charts before installing.
• This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
• The user is responsible for the selection of bolting and gasket materials which will
fall within the limits of the flange and its intended use, and which are suitable for
the service conditions.
Note: Installation shall only be performed by qualified personnel and in accordance with
local governing regulations.
Mounting Location
Recommendations:
• Ambient temperature within –40 to +80 °C (–40 to +176 °F).
• Easy access for viewing the display and programming via the hand programmer.
• An environment suitable to the housing rating and materials of construction.
• Keep the sound path perpendicular to the material surface.
Precautions:
• Avoid proximity to high voltage or current wiring, high voltage or current contacts, and to
variable frequency motor speed controllers.
• Avoid interference to the sound path from obstructions or from the fill path.
Fill
The sound path should be:

pipe
• perpendicular to the
monitored surface
• clear of rough walls, rungs
seams, rungs, or
other obstructions seams
10°
• clear of the fill path

X38 Cone Crusher
Mounting Instructions
Note: Ideally, mount SITRANS Probe LU so that the face of the transducer is at least
300 mm (1 ft) above the highest anticipated level.
English
SITRANS Probe LU is available in three thread types: 2" NPT, 2" BSP, or PF2/G.
1. Before inserting SITRANS Probe LU into its mounting connection, ensure that the threads
are of the same type to avoid damaging them.
2. Simply screw SITRANS Probe LU into the process connection, and hand tighten.
Wiring
Power1
WARNINGS:
DC terminals shall be supplied from an SELV 1 source in accordance with IEC-
1010-1 Annex H.
All field wiring must have insulation suitable for rated voltages.
Connecting SITRANS Probe LU

Notes: cover screws
• For detailed information on Intrinsically
Safe set-ups, please see the full manual. hinged lid
• Use shielded, twisted pair cable (wire
gauge AWG 22 to AWG 14 /0.34 mm2 to
2.08 mm2).
• Separate cables and conduits may be
required to conform to standard
instrumentation wiring practices, or
electrical codes.
• The non-metallic enclosure does not
provide a continuous ground path threaded water-
connection tight gland
between conduit connections: use
grounding-type bushings and jumpers.
1. Safety Extra Low Voltage

X38 Cone Crusher
1. Strip the cable jacket for approximately 70 mm

(2.75") from the end of the cable, and thread the terminals for A
m
loop current
wires through the gland1.
2. Connect the wires to the terminals as shown
English
above: the polarity is identified on the terminal

block.
3. Tighten the gland to form a good seal.
4. Close the cover and tighten screws: please do
cable
not overtighten screws. Recommended torque is
1.1 to 1.7 N-m (10 to 15 in-lb).
RUN Mode and PROGRAM Mode

SITRANS Probe LU has two modes of operation: RUN and PROGRAM.
SITRANS Probe LU automatically starts in RUN mode when power is applied, and detects the
material level. The primary reading displays the material level (in meters) referenced from
Empty (process empty level). This is the default start-up display mode.
System status is displayed on the LCD, or on a remote communications terminal.
RUN Mode Display1

23
Use the hand programmer to control the display.
Normal operation Failsafe operation
2 3 3
1 1
4 4
6 5 5
m 6 m
1 – Primary Reading (displays level, distance, or volume2, in either units or percent).

2 – Secondary Reading (displays Parameter number for Auxiliary Reading3)
3 – Echo status indicator: Reliable Echo or Unreliable Echo
4 – Units or Percent
5 – Active bar graph represents material level
6 – Auxiliary Reading (depending on the parameter selected, it displays milliAmp value,
distance, or echo confidence, with units where applicable.)
1. If cable is routed through conduit, use only approved suitable-size hubs for waterproof application.
2. For details on displaying flow instead of volume, please see P050 in the full manual.
3.
Press to display the auxiliary reading field when in RUN mode.

X38 Cone Crusher
If the echo confidence drops below the echo confidence threshold, the failsafe timer starts
running. When the timer expires, the letters LOE (Loss of Echo) alternate with the reading
every two seconds, and the Reliable Echo indicator is replaced by the Unreliable indicator.
When a valid reading is received, the level reading display returns to normal operation.
English
PROGRAM Mode Display
2 3 1– Primary Reading (displays parameter value)
2– Secondary Reading (displays parameter number)
1
3– Programming indicator
4 4– Auxiliary Reading (displays parameter names for P001 to
P010, if a language is selected. It displays the index value
for indexed parameters, such as P054).
Programming
• Set parameters to suit your specific application.
• Activate PROGRAM mode at any time, to change parameter values and set operating
conditions.
• For local programming, use the Siemens Milltronics hand programmer.
• For programming from a distance, use either a PC running SIMATIC PDM, or a HART
handheld communicator.
Hand programmer
Key Programming Mode
For direct access to SITRANS Probe LU,
point the programmer at the SITRANS Decimal point1
Probe LU display and press the keys.
(For detailed instructions, see the next Negative value
page.)
CLEAR value
hand programmer TOGGLE between Units and % on parameter
value
display End PROGRAM session and enable RUN mode
Update echo quality parameters
max. 600 mm Parameter scroll-up

(2 ft)
Parameter scroll-down
DISPLAY opens parameter fields
ENTER the displayed value
1.
Press plus three-digit parameter number, to set
parameter to show in the auxiliary display.

X38 Cone Crusher
Low temperature effects on RUN/PROGRAM modes

If the internal temperature falls to –30 oC (–22 oF) or below, it will affect both RUN and
PROGRAM modes.
English
RUN mode will operate normally, with the following exceptions:

• hand programmer operation is disabled
• the LCD displays only limited information: the bar graph and the reliable/unreliable echo
indicator
PROGRAM mode:
• hand programmer operation is disabled
Security: (P000: Lock)

Value Description
Value stored in P069 * Lock off: programming permitted
other Lock activated: no changes permitted
* Factory setting for P069 is 1954: after a new value is entered and accepted, it becomes the
default setting.
Activating SITRANS Probe LU

Power up the instrument. SITRANS Probe LU starts in RUN mode.
Notes:
• Keep infrared devices such as laptops, cell phones, and PDA’s, away from SITRANS
Probe LU to prevent inadvertent operation.
• The following instructions apply when using the Hand Programmer.
• Do not use the Hand Programmer at the same time as SIMATIC PDM, or erratic operation
may result.
• Press PROGRAM then DISPLAY to access PROGRAM mode, and press
PROGRAM to return to RUN mode.
• You do not need to key in initial zeros when entering a parameter number: for example,
for P005, key in 5.

X38 Cone Crusher
Accessing a parameter
1. Press PROGRAM then DISPLAY , to activate PROGRAM Icon
PROGRAM mode.
English
Parameter Number
2. Either use the ARROW keys to scroll to a Parameter Value
different parameter, or:
3. Press DISPLAY to open the Parameter Number
field. current value
4. Key in the desired parameter number followed by
ENTER .
5. For example: press then .
6. The LCD displays the new parameter number and
value.
Changing a Parameter Value

Notes:
• Security must be disabled to enable programming: set P000 to the Unlocked Value stored
in P069. (A remote master can still change configuration, if P799 is set to allow this.)
• Invalid entries will be rejected or limited.
• CLEAR can be used to clear the field.
1. Key in the new value.
2. Press ENTER to set the value.
Parameter Reset to Factory Default
1. Scroll to the parameter or enter its address.
2. Press CLEAR then ENTER . The value returns to the default setting.
Master Reset (P999)

Returns all parameters except P000 and P069 to default settings. (The learned TVT curve is not
lost.)
1. Press PROGRAM , then DISPLAY to activate PROGRAM mode.
2. Press DISPLAY to open parameter fields.
3. Key in 999.
4. Press CLEAR then ENTER , to Clear All and initiate
reset. The LCD displays C.ALL.
5. Reset complete. (Reset takes several seconds to complete.)

X38 Cone Crusher
Quick Setup: steps 1 to 10

Note: Default values (factory settings) are marked by an asterisk (*) in the tables.
English
1. Select language (P010: Language)

0 * Numeric/None ENGLISH DEUTSCH FRANÇAIS ESPAÑOL
P000 LOCK VERRIEGELG VERROUIL BLOQUEO
1 English
P001 OPERATION BETRIEB FONCTIONMT FUNCIONAM.
Values 2 German P003 MEAS RESP REAKTIONSZ TEMPS REP. TIEMPO R.
3 French P004 ANTENNA ANTENNE ANTENNE ANTENA
P005 UNITS EINHEIT UNITES UNIDADES
4 Spanish
P006 EMPTY MESSBER. VIDE VACIO
P007 SPAN MESSSPANNE PLAGE RANGO
P010 LANGUAGE SPRACHE LANGUE IDIOMA
2. Set P001: Operation (measurement mode)

Notes:
• Setting P001 resets Span (P007), unless Span has previously been set to a different value.
• Changing P001 may reset Output Function (P201): this applies to HART only.
Level returns distance to material level referenced from Empty (process empty level). The
1 *
Values reading is returned in volumetric units if parameters 050 to 055 are set to enable this.
2 Space returns distance to material level referenced from Span (process full level).
3 Distance returns distance to material level from reference point (transducer face).
mA Output with Level, Space, and Distance operation

Level Space Distance
(P001 = 1) (P001 = 2) (P001 = 3)
transducer
0%
face (4 mA)
(20 mA) Span (4 mA) Span
Span 100% 0% Distance
Space
P007
P006
Level
Empty Empty
Empty 0% 100% 100%
(4 mA) (20 mA) (20 mA)

X38 Cone Crusher
3. Set Measurement Response (P003) 4. Select measurement units (P005)

1 * slow 0.1m/minute 1 * meters
Values 2 medium 1m/minute 2 centimeters
English
3 fast 10m/minute Values 3 millimeters
Set P003 to a measurement response speed 4 feet
just faster than the maximum filling or 5 inches
emptying rate (whichever is greater).
5. Set process empty level (P006: Empty) Level Setup

transducer
Note: face
• P006 and P007 are interlinked: see
notes attached to P007. Span 100%
0.0000 to 6.000 m (20 ft) or

Range P007
Values 0.0000 to 12.000 m (40 ft)
P006
Default Maximum range
Level
Empty can be set to any distance: not necessarily
the bottom of the tank. Empty 0%
6. Set measurement range (P007: Span)1

0.0000 to 6.000 m (20 ft) or
Range Span can be set at any distance above
0.0000 to 12.000 m (40 ft)
Values Empty level
5.725 m (18.78 ft) or
Default
11.725 m (38.47 ft)
.
Notes:
• Setting P006 resets Span, if it has not previously been set to a different value.
• The default setting for Span is based on Operation (P001) and Empty (P006). Span is set to
Empty minus 110% of Blanking distance1, unless Operation is set to distance (P001=3). In
this case, Span is set to Empty distance.
• Always prevent the monitored surface from approaching within 0.3 m (1 ft) of the
transducer face. This provides a 0.05 m (2") safety margin, as 0.25 m (10") is the minimum
distance detectable.
1. Default setting for Blanking is 0.25 m (10").

X38 Cone Crusher
7. Minimize false reflections: Set P838 (Auto False Echo Suppression Distance)
Use P838 and P837 Maximum range:
Range
together: follow the 0.000 to 6.000 m (20 ft) or
Value (depends on model)
instructions for P837. 0.000 to 12 m (40 ft)
English
Default 1.000 m (3.28 ft)
8. Enable False Echo Suppression: set P837 (Auto False Echo Suppression)
0 Off
Value 1 * Use "learned" TVT
2 "Learn"
Using P837 and P838 (perform this function at low tank levels)
The TVT (Time Varying Threshold) curve sets a threshold which screens out false echoes1. If
SITRANS Probe LU displays an incorrect full level, or if the reading fluctuates between a false
high level and a correct level, use P838 and P837 together to elevate the TVT (Time Varying
Threshold) in this region and de-sensitize the receiver from any ‘base noise’ caused by internal
transducer reflections, nozzle echoes, or other vessel false echoes2.
. Using P837 and P838 (continued)
Notes:
• Use this function only if there is a minimum distance of 2 meters from SITRANS Probe LU
to the material. This function works best if the vessel is empty or nearly empty.
• Set P837 and P838 during start up, if possible.
• If the vessel contains an agitator, the agitator should be running.
a. Determine the actual distance from the transducer face to the material level.
b. Select P838 and key in [distance to material level – 0.5 m].
c. Select P837, then press 2 (Learn) and ENTER . P837 will automatically revert to 1 (use
Learned TVT) after a few seconds.
9. Return to RUN
Press PROGRAM to return to RUN mode: setup is complete.
1. False echoes can be caused by obstructions in the beam path.

2. For more details on Auto False Echo Suppression, please see the full manual.

X38 Cone Crusher
SITRANS Probe LU Communications: HART

Note: See mA Output with Level, Space, and Distance operation on page 10 for an
illustration of the mA output with different modes of operation.
English
• You will need the full manual to acquire the list of applicable parameters.
• Please contact your local representative concerning the availability of the HART DD for
SITRANS Probe LU.
• We recommend that you use SIMATIC Process Device Manager (PDM) to program your
instrument.
Maintenance
SITRANS Probe LU requires no maintenance or cleaning.
Unit Repair and Excluded Liability

For detailed information, please see the inside back cover.
Instructions specific to hazardous area installations

(Reference European ATEX Directive 94/9/EC, Annex II, 1/0/6)
The following instructions apply to the SITRANS Probe LU covered by certificate number SIRA
03ATEX2142X:
1. For use and assembly, refer to the main instructions.
2. The equipment is certified for use as Category 1G equipment.
3. The equipment may be used with flammable gases and vapors with apparatus groups IIA,
IIB, and IIC, and temperature classes T1, T2, T3, and T4.
4. The equipment is certified for use in an ambient temperature range of –40 °C to +80 °C.
5. The equipment has not been assessed as a safety related device (as referred to by
Directive 94/9/EC Annex II, clause 1.5).
6. Installation and inspection of this equipment shall be carried out by suitably trained
personnel in accordance with the applicable code of practice (EN 60079-14 and EN 60079-
17 in Europe).
7. Repair of this equipment shall be carried out by suitably trained personnel in accordance
with the applicable code of practice (e.g. EN 60079-19 within Europe).
8. Components to be incorporated into or used as replacements in the equipment shall be
fitted by suitably trained personnel in accordance with the manufacturer’s
documentation.
(continued on next page)

X38 Cone Crusher
9. It is the responsibility of the user to ensure that manual override is possible in order to
shut down the equipment and protective systems incorporated within automatic
processes which deviate from the intended operating conditions, provided that this does
not compromise safety.
English
10. The ‘X’ suffix to the certificate number relates to the following special conditions for safe
use:
Parts of the enclosure may be non-conducting and may generate an ignition-
capable level of electrostatic charge under certain extreme conditions. The
user should ensure that the equipment is not installed in a location where it
may be subjected to external conditions (such as high-pressure steam) which
might cause a build-up of electrostatic charge on non-conducting surfaces.
11. If the equipment is likely to come into contact with aggressive substances, then it is the
responsibility of the user to take suitable precautions that prevent it from being adversely
affected, thus ensuring that the type of protection is not compromised.
Aggressive substances:e.g. acidic liquids or gases that may attack metals, or
solvents that may affect polymeric materials.
Suitable precautions: e.g. regular checks as part of routine inspections or
establishing from the material’s data sheet that it is
resistant to specific chemicals.
12. Equipment Marking:
The equipment marking contains at least the information on the product nameplate,
shown on the inside front cover of this manual.

Models 38, 44, 52, 57 and 68 SBS
Cone Crushers
Operation and Maintenance
ISSUE DATE: 12/06 TP500
SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.
! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!
• Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
• Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.
• Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.
• Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.
• Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and
maintenance schedules.
• Read the operator’s manual for the equipment that you operate. Be sure that you fully understand all phases
of operation for each machine. A careful and well-trained operator is the best insurance against an accident.
• Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.
• All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the user’s responsibility. Such equipment must be installed wherever appropriate and
maintained as required.
• It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.
Foreword
INTRODUCTION ORDERING REPLACEMENT PARTS
The information, drawings, and pictures provided in this A separate parts catalog has been provided with this manual.
manual will help you to achieve optimum performance from Refer to the parts catalog when ordering Telsmith parts. If
your Telsmith, Inc. product. It contains safety, operation, your parts catalog has been lost or damaged, new copies are
maintenance, service, and repair information on the machine available from your local approved Telsmith Distributor or
to assist you in your operation. the Telsmith Parts Department.
Please note that some features shown in this manual may not To ensure that you receive the correct parts for your machine,
be present on your machine. Some equipment described may always include the model number and serial number when
be optional at extra cost, or available only on selected models. ordering.
The data and instructions contained in this manual are based
on the latest information at the time of publicaion. Telsmith's MODEL and SERIAL NUMBER PLATE
poli cy o f cont inuo us i mprovem ents, features and LOCATION
specifications are subject to change without notice.
Actual dimensions, weights, and clearances may be different
than shown, due to fabrication variables, custom engineering
or optional equipment.
HOW TO CONTACT TELSMITH INC.

Use the following information when you wish to contact
Telsmith:
• General: Phone (262) 242-6600
FAX (262) 242-5812
• Parts: Phone (800) 688-6601
FAX (262) 242-7861
• Written: Telsmith, Inc.
10910 N. Industrial Drive
P.O. Box 539
Mequon, WI 53092-0539
U.S.A.
• Send all e-mail to:
parts@telsmith.com
REQUESTING SERVICE ASSISTANCE

If service assistance is required or you have questions about
maintenance or repair procedures in this manual, please
contact your local approved Telsmith Distributor. If
additional assistance is necessary, contact the Telsmith
Service Department.
Service technicians are available by telephone from 8:00 a.m.
to 4:30 p.m. CST, Monday through Friday, except holidays. Model and serial numbers are located on a data plate attached
To ensure faster response, always have your machine’s model to the machine main frame. Always lockout power and tag
and serial numbers ready when calling. controls before reading data plate!
12/06 227
Foreword Operation and Maintenance
Extec SBS Cone Crusher
SERVICE BULLETINS CONTACTS

Telsmith periodically issues service bulletins to inform TELSMITH PARTS DEPARTMENT CONTACTS
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins Name:
before starting any maintenance or service work. Phone (Office):
Phone (Cell):
SAFETY FAX:
All quarry personnel operating or servicing the machine must
read and fully understand the information included in Name:
Chapter 1, Safety of this manual.
Phone (Office):
Phone (Cell):
ILLUSTRATIONS
FAX:
This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed
for instructional purposes or to provide greater clarity. TELSMITH SERVICE DEPARTMENT CONTACTS
However, to prevent serious personal injury or death, always
be sure all such equipment is installed before operating the
Name:
product.
Phone (Office):
INSTALLATION & ASSEMBLY DRAWINGS Phone (Cell):
Installation and assembly drawings (blueprints) are provided FAX:

with all new Telsmith products. These drawings are normally
included with the technical manuals but may be shipped TELSMITH APPROVED DISTRIBUTOR CONTACTS
separately for some orders.
The drawings include specifications, dimensions and other Name:
information for use during installation and assembly
Phone (Office):
procedures. Contact your local Telsmith dealer or the
Telsmith Service Department if you have any questions about Phone (Cell):
information contained on the drawings. FAX:
If the drawings are lost, replacement copies may be ordered

from your local Telsmith dealer or the Telsmith Parts OTHER CONTACTS
Department.
Name:
Phone (Office):
Phone (Cell):
FAX:
Name:
Phone (Office):
Phone (Cell):
FAX:
228 12/06
Chapter 1
Safety
CONTENTS
Page
GENERAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hazard Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Who Must Use Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
What Is Lockout/Tagout? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
When Must Lockout/Tagout Occur? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
How Is Lockout/Tagout Performed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
When Can Lockout/Tagout Devices Be Removed? . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lockout/Tagout Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Additional Lockout/Tagout Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
QUARRY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Know Your Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Be Prepared for Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wear Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Observe Personal Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Help Prevent Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
High Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Avoid Alcohol and Other Drugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Be Aware of Your Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Practice Good Housekeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Falling Rocks or Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Inspect and Maintain Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
EQUIPMENT INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Equipment Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Foundations and Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Safety Operation and Maintenance
Operator Vantage Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Customer Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Pressurized Systems
(Hydraulic and Pneumatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Welding, Cutting or Grinding on Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Clearing Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Disposal of Excess Fuels, Lubricants and Liquids . . . . . . . . . . . . . . . . . . . . . . . 1-15
Flammable and Combustible Liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Forming Wire Rope Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Connecting Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Fiber or Synthetic Slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
TRANSPORTATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

MAINTENANCE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Types of Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Operation and Maintenance Safety
GENERAL SAFETY Hazard Statements

It is the responsibility of the quarry management team to
develop a comprehensive safety awareness program, and to ! DANGER
ensure that all quarry workers and support personnel receive Danger indicates an imminently hazardous situation which, if
appropriate safety training as required by federal, state and not avoided, will result in death or serious injury.
local regulations.
Be sure all operating, maintenance, service and support ! WARNING
personnel read and understand the contents of this manual,
including the safety information in this Chapter 1. Warning indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
There are standard safety rules, but each situation has its own
conditions that cannot always be covered by these rules.
Therefore, quarry personnel must continually watch for ! CAUTION
possible safety hazards and be prepared to take prompt Caution indicates a potentially hazardous situation which, if
corrective action when deficiencies in safety procedures are not avoided, may result in minor or moderate injury.
found.
Failure to observe the precautions contained in this chapter Advisory Statements
can result in serious personal injury and even loss of life. As
with most industrial work environments, a careful operator is NOTE:
the best insurance against an accident.
A statement used to draw attention to procedures and
The complete observance of one simple rule would prevent practices. Advisory in nature to the operation, maintenance,
many unnecessary injuries and deaths each year. This rule is: service, and repair of the machinery.
“Never attempt to clean, lubricate, repair or adjust any
machinery or equipment unless it is stopped and properly IMPORTANT:
locked out and tagged out.” A statement used to draw attention to procedures and
Please note that this chapter is intended only as a brief review practices that need to be followed to prevent damage to the
of basic quarry safety precautions and procedures. The machine.
general guidelines included in the following paragraphs
should not be considered in lieu of a quarry’s official safety
procedures, insurance company requirements, or applicable
federal, state and local regulations.
PRECAUTIONARY STATEMENTS
Throughout this manual, you will see the following
Precautionary Statements listed below. These are used to
emphasize certain hazards or precautions related to
procedures in this manual.

There are many maintenance procedures contained LOCKOUT/TAGOUT

throughout this manual. All machinery that is maintained in
good working condition minimizes safety hazards and Who Must Use Lockout/Tagout?
emergencies.
Quarry owners, managers, and safety officers must be aware
Refer to Figure 1-1 for examples of Precautionary of OSHA’s “lockout/tagout” standard: 29 CFR, Section
Statements. 1910.147, The Control of Hazardous Energy. This standard is
also recognized by MSHA.
All mechanics, maintenance personnel, operators, and
electricians must fully understand and comply with this
NOTE: standard to ensure the safety of all employees.
If installing banded V-belts, multiply the deflection

force called for in Table 7-3 by the number of V-
belts in the band.
IMPORTANT:
If obvious signs of trouble or unusual noises occur
during star t-up, stop the crusher as soon as
possible.
! CAUTION
Failure to install rotor locking pin after upper
rear frame has been opened will allow rotor
to turn. Serious personal injury may occur.
! WARNING
Failure to follow the instructions and
precautions below may result in serious
personal injury or death.
• Stop crusher and lockout/tagout main drive
p o w e r s o u rc e a n d c o n t ro l s . Wa r n a l l
personnel that crusher is being serviced.
! DANGER
HAZARDOUS VOLTAGE! Disconnect and
l o c k o u t / t a g o u t p o w e r s o u rc e b e f o r e
servicing. Failure to observe this precaution
will likely result in serious injury or death.
Figure 1–1. Sample Precautionary Statements

What Is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who
install, operate, repair, maintain, service, or otherwise disable
machines, equipment, or electrical energy systems are
protected from harm due to unexpected energization or start-
up of equipment, or the release of stored energy by:
Lockout. The placement of a lockout device on an
energy isolating device, in accordance with an
established procedure, ensuring that the energy
isolating device and the equipment being controlled
cannot be operated until the lockout device is
removed.
Lockout device. A device that utilizes a positive
means such as a lock, either key or combination
type, to hold an energy isolating device in the safe
position and prevent the energizing of a machine or
equipment. Included are blank flanges and bolted
slip blinds.
Tagout. The placement of a tagout device on an
energy isolating device, in accordance with an
established procedure, to indicate that the energy
isolating device and the equipment being controlled
Figure 1–2. Lockout/Tagout
may not be operated until the tagout device is
removed.
When Must Lockout/Tagout Occur?
Tagout device. A prominent warning device, such
Lockout/tagout of equipment must occur whenever service
as a tag and a means of attachment, which can be
or maintenance is performed, and injury could occur due to
securely fastened to an energy isolating device in
the unexpected energization or start-up of equipment, or the
accordance with an established procedure, to
release of stored energy.
indicate that the energy isolating device and the
equipment being controlled may not be operated In general, lockout/tagout procedures must be performed
until the tagout device is removed. under the following circumstances:
• Before cleaning, lubricating, adjusting or repairing
machinery or equipment.
• Before working on electrical, hydraulic or pneumatic
circuits or devices.
• Before clearing jammed mechanisms, machinery or
equipment.
• Before removing guards or other protective devices.
• Whenever a machine or its controls will be left
unattended.

How Is Lockout/Tagout Performed? In situations in which lockout or tagout devices must be

temporarily removed to test or position the machinery or
OSHA has identified the following step-by-step lockout/
component thereof, the following sequence of actions shall be
tagout procedure:
followed:
1. Prepare for shutdown – Before shutting down a piece of
1. Clear the machine or equipment of tools and materials.
equipment, know the type and magnitude of the energy that
powers it, the hazards of that energy, and how to control it. 2. Remove employees from the equipment area.
Warn all employees that the machinery is about to be shut
3. Remove the lockout or tagout devices following proper
down.
procedures.
2. Shut down the equipment – After warning all
4. Energize and proceed with testing or positioning.
employees, shut down the machine, equipment, or electrical
system by the normal stopping procedure. 5. De-energize all systems and reapply lockout/tagout
devices to continue the servicing and/or maintenance.
3. Isolate the equipment – Disengage all isolating devices,
both primary and secondary, so that the equipment is isolated
from all of its energy sources (electrical, mechanical,
hydraulic, pneumatic, etc.).
4. Apply lockout/tagout devices – Attach lockout/tagout
devices (according to your company’s safety program) in
such a manner that the isolating device (circuit breaker,
control, etc.) will be held in a safe or off position. Attach tags
to alert others that the machinery is being serviced.
5. Control stored energy – any potentially hazardous stored
energy (electrical, mechanical, hydraulic, pneumatic, etc.)
that remains must be released, dissipated, restrained, or
otherwise rendered safe. If stored energy reaccumulates,
monitor it until the possibility of accumulation no longer
exists.
6. Verify that equipment is isolated – After warning all
employees to stay clear, engage the start button to confirm the
machine is inoperable. Return the control to the OFF position
before proceeding with servicing.
When Can Lockout/Tagout Devices Be

Removed?
Lockout/tagout devices can be removed only after the
following conditions are met:
• All guards and protective devices are properly reinstalled.
• All tools and repair equipment are removed from the
equipment and the immediate area.
• All mechanics and other personnel are clear of the
equipment and its immediate area.
• All personnel have been warned that the equipment is
about to be restarted (sound warning horn or activate
warning lights).
After removing lockout/tagout devices, always use the
normal start-up procedure as described in the operator’s
manual for the machinery.

Lockout/Tagout Devices • Your company’s lockout/tagout program may be

somewhat different than described in this manual. If so, be
Lockout/tagout devices include:
sure to completely follow your company’s official
1) locks policies and procedures when lockout/tagout is
2) tags and labels necessary. Consult your company’s safety officer if you
3) multiple lockout devices have any questions.
Lockout devices and tagout devices shall be singularly • A lock must have only one user and one key. Anyone who
identified, shall be the only device(s) used for controlling installs a lock must keep the key in their possession at all
energy, shall not be used for other purposes, and shall meet times. Except in an emergency situation, only the person
the following requirements: that installs a lock is authorized to remove it.
• Lockout and tagout devices shall be capable of • To prevent accidental start-up, never give your lock or its
withstanding the environment to which they are exposed key to another employee.
for the maximum period of time that exposure is expected.
• Your key must open your lock only. Your key should not
Tagout devices shall be constructed and printed so that
be capable of opening any other locks. Keys for other
exposure to weather conditions or wet and damp locations
locks should not be capable of opening your lock.
will not cause the tag to deteriorate or the message on the
tag to become illegible. • Except in an emergency situation, never attempt to
remove anyone else’s lock. Do not allow others to remove
• Lockout and tagout devices shall be standardized within
your lock.
the facility in at least one of the following criteria: color,
shape, or size, and additionally, in the case of tagout • When disconnecting power, be sure that the circuit
devices, print and format shall be standardized. breaker handle (or other isolating device) is in the OFF
position. Accidentally locking a control in the ON
• Lockout devices shall be substantial enough to prevent
position could result in serious personal injury or death.
removal without the use of excessive force or unusual
techniques, such as with the use of bolt cutters or other • If two or more people are working on a machine, a
metal cutting tools. multiple lockout device must be used to prevent
accidental start-up in the event that one person finishes
• Tagout devices, including their means of attachment, shall
working before another.
be substantial enough to prevent inadvertent or accidental
removal. Tagout device attachment means shall be of a • Each lock must have a tag. If two or more people are
non-reusable type, attachable by hand, self-locking, and working on a machine, each person must attach a separate
non-releasable with a minimum unlocking strength of no tag to their lock. Never attach a lock without a tag.
less than 50 pounds and having the general design and
• Never use tags alone. A tag should always be
basic characteristics of being at least equivalent to a one-
accompanied by a lock which prevents the isolating
piece, all-environment-tolerant nylon cable tie.
device from becoming energized.
• Lockout devices and tagout devices shall indicate the
identity of the employee applying the device(s).
• Tagout devices shall warn against hazardous conditions if
the machine or equipment is energized and shall include a
legend such as the following: Do Not Start. Do Not Open.
Do Not Close. Do Not Energize. Do Not Operate.
A multiple lockout device must be used when two or more
people are working on a piece of equipment. This allows each
person to install their own lock and tag.
Lockout/Tagout Rules
• Always lockout/tagout any machinery before performing
any adjustment, inspection, lubrication, maintenance or
repair procedures. Failure to observe this precaution may
result in serious personal injury or death.

Additional Lockout/Tagout Requirements • Become familiar with the controls, functions and settings
of each machine. Fully understand all phases of each
• Be sure that the power is COMPLETELY turned off. A
machine’s operation.
motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical • Be sure that you completely understand and follow all
components may still be energized. Use a voltmeter and/ start-up and shutdown procedures as described in the
or ammeter to verify that all electrical circuits are manufacturer’s manuals.
completely dead.
• Be familiar with the safety labels on your equipment, and
• Always be sure that all peripheral equipment, such as feed the hazards against which they warn.
conveyors, grizzly feeders and discharge conveyors, have
• Check the legibility of all safety labels every day. Order
lockout/tagout devices attached. Serious personal injury
new labels from the machinery manufacturer if they
or death can result if any of these items starts
become illegible or worn.
unexpectedly while service work is in progress.
• Although lockout/tagout procedures are most commonly Be Prepared for Emergencies
associated with electrical systems, be aware that
• Know the proper emergency shutdown procedures for the
hydraulic, pneumatic and mechanical systems must also
equipment you operate.
be tagged and locked out before servicing. This may
involve the lockout/tagout of valves, levers and other • Know where fire extinguishers are kept and how to use
non-electrical devices. them. Be sure that fire extinguishers are properly rated,
and that they remain fully charged and ready for use at all
• For machinery powered by internal combustion engines
times.
(diesel, gas, etc.), always disconnect batteries and shut off
fuel supply before servicing the machinery. Lockout/ • Know the procedure for contacting emergency medical
tagout engine controls to ensure that engine is not personnel. Keep a list of emergency phone numbers
accidentally started while the machinery is being handy at all times.
serviced.
• Know where a first-aid kit, stretcher and other emergency
• Always be sure that all hydraulic or air pressure is supplies are kept. Be sure that first aid supplies are
completely relieved before working on hydraulic or properly maintained and ready for use.
pneumatic systems. Dangerous pressures can be present,
• Make sure that a clear path to emergency equipment and
even when equipment is turned off and locked out.
exits is always maintained. Do not allow equipment,
• After maintenance or repairs are completed, always warn spilled materials or other obstructions to get in the way.
all employees that the machinery is about to be restarted.
• Know how to report accidents. Always report all
Be sure no one is on or near the equipment before a lock
accidents immediately to the appropriate supervisor.
and tag is removed.
• As a precaution, always activate a warning horn or light
before restarting the machinery. This will provide
additional warning for personnel to stay clear of
machinery that is about to be started.
QUARRY SAFETY
Know Your Equipment
• Read and understand the manufacturer’s operation and
maintenance manuals for all machinery and equipment
that you operate. Be sure that all hazard statements
contained within the manuals are completely understood.
• Allow only trained and authorized personnel to operate
and maintain machinery.

Wear Personal Protective Equipment (PPE) • To avoid back injuries, always use proper lifting
techniques to safely lift heavy objects. Lift with your legs
Aggregate processing and handling can be a dangerous
and keep your back straight. Keep the materials or object
process. To reduce the risk of serious injury or death to
close to your body. Have a co-worker assist you if the load
personnel, observe the following precautions:
cannot be lifted safely by one person.
• Wear safety glasses or goggles whenever outside of an
• Before starting the machinery, check that no personnel are
approved operator’s enclosure. Failure to wear
inside, on, under or beside the equipment. Unless
appropriate eye protection can result in permanent eye
absolutely necessary, do not allow anyone to be on or near
injuries and loss of sight.
the equipment while it is operating.
• During initial start-up of machine, sound pressure levels
• Never attempt to catch falling materials or objects.
should be taken near machine to determine what level of
hearing protection is required. Wear appropriate ear • Be aware of flammable liquids and other potential fire
protection when working within 50 feet of any operating hazards. Do not smoke when refilling engines or using
quarry machine and in other areas where noise levels are cleaning solvents.
high. Prolonged exposure to high noise levels can cause
• Do not stand under equipment or components that are
permanent hearing loss.
being hoisted or suspended. Never allow other quarry
• Wear steel-toe safety boots, heavy-duty gloves and a hard personnel to do so.
hat. This equipment is mandatory in most areas of the
• Before you assemble, operate, clean, lubricate, or adjust
quarry.
machinery, be sure to read and understand all procedures
• Always use authorized respirators when working in and contained in the machinery manufacturer’s manual.
around high-dust areas. Prolonged exposure to dust
• Be sure to operate quarry machinery in compliance with
particles can cause silicosis of the lungs. This, over a long
current OSHA and MSHA regulations, and all applicable
time period, can cause serious ilness or death.
federal, state or local regulations.
• Other personal protective equipment may be necessary
• Be sure that all guards and other safety devices are
for your specific job assignment, such as a full face shield
correctly installed and tightly secured before starting the
and safety harness. Wear or use these items when
crusher. Stay clear of rotating or moving parts during
necessary and as required by applicable federal state and
crusher operation.
local regulations.
Observe Personal Safety Precautions

• Never wear loose or ragged clothing when working on or
around rotating power equipment. Avoid wearing
necklaces, rings or other jewelry. These items can become
caught or tangled in the machinery, resulting in severe
personal injury or death.
• Keep hair short, if possible. Keep long hair securely tied
up to prevent it from becoming caught in the machinery.
• Be especially careful whenever using wet walkways,
platforms, or ramps. The combination of rock dust and
wet metal can create an extremely slippery surface. Keep
all walkways and other access structures clean, dry and
free of grease or oil.
• Use walkways and ladders when working near machinery,
or observing its operation. Use a safety harness when
necessary. Keep handrails and machine contact surfaces
clean.

Help Prevent Accidents • Be aware of idle machinery that could start up without
warning. Stay clear of such machinery and the immediate
• Do not allow unauthorized personnel in or near the work
area.
area. Never allow unauthorized personnel to operate,
adjust, maintain or repair machinery. • Be aware of overhead obstructions, such as conveyors,
support structures or power lines.
• Allow only properly trained and experienced personnel to
operate machinery. Be sure inexperienced operators are
carefully supervised at all times. Practice Good Housekeeping
• Do not store tools or equipment on walkways.
• Do not allow personnel to be near loading areas, or
anywhere else that falling or ejected material could hit • Be sure that all walkways, platforms, stairs and ramps are
them. kept free of spilled material and trash. A build-up of
material in these areas can cause slips and falls. Make
• Use extreme caution if the machinery must be operated
repairs as required in areas where spillage is present.
for inspection or observation purposes. Stay a safe
distance from the machinery and wear appropriate • Do not allow machinery to become buried under piles of
personal protective devices. spilled material. This will make the machinery more
difficult to inspect and may hide broken welds, loose
• Before making repairs to the machinery, always clear all
fasteners and other serious problems that could cause a
quarry material from the feed and discharge devices
safety hazard.
(feeders, conveyors, chutes, etc.).
• Keep the areas around control panels and machinery free
• In areas that present a danger of falling, use an appropriate
of spilled material. Free access must be maintained at all
fall protection device, such as a safety harness and
times. In the event of an emergency, quick access to
lifeline.
controls could prevent injury or death.
• Always report any unsafe conditions or defective
• Clean up spilled fuel or oil immediately to eliminate
equipment to the appropriate supervisor.
slipping hazards. If necessary, use an oil absorbent.
High Operating Temperatures • Always be sure that power is tagged and locked out before
cleaning spilled material or oils. Never clean up these
• The equipment generates heat during operation resulting
items while the machinery is operating.
in surface temperatures that may sometimes exceed 60 °C
(140 °F). For your safety, we recommend to let the
equipment cool before attempting to perform Falling Rocks or Material
maintenance. CAUTION - There is a risk of burn if the • Due to the unpredictable nature of aggregate and mineral
equipment is handled before cooling. handling, rocks may sometimes fall or be ejected from the
equipment. The user is cautioned to prevent potential
Avoid Alcohol and Other Drugs falling debris though intelligent design of the surrounding
structure by using guards and skirting where appropriate.
• Do not operate or work near quarry machinery when
CAUTION - A falling debris hazard exists around the
under the influence of alcohol or other drugs. These
equipment. Maintain a safe distance and wear Personal
substances can result in reduced alertness and impaired
Protective Equipment such as your hard hat, safety shoes
judgement. Serious personal injury or death could result.
and safety glasses. Additional safety warning decals have
• Some prescription and non-prescription medications can been provided for your convenience to post near the
cause drowsiness or other adverse side effects. Do not equipment.
operate or work near quarry machinery when under the
influence of such medications.
Be Aware of Your Surroundings

• The quarry environment contains many situations that are
potentially hazardous. Use extreme caution to avoid being
struck by haul trucks, loaders and other quarry mobile
equipment.

Inspect and Maintain Machinery • All support structures designed and manufactured by
others must be of adequate strength and size to resist the
• Always perform a safety inspection at the beginning of
weight of loaded machinery and any vibration which may
each shift. Refer to the machinery manufacturer’s
occur.
operation and maintenance manuals for detailed pre-start-
up inspection and maintenance procedures. • Structures and foundations should be designed and
constructed to handle dynamic forces up to 2.5 times the
• Test all warning devices before starting the machinery to
weight of the machinery.
ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks. • All walkways, platforms, handrails, stairs and guards
designed by others must meet all local, state and federal
• Be sure that any defective components or systems are
regulations.
properly repaired by a qualified technician before the
machinery is started. Immediately report any serious Typical installations of Telsmith equipment will include an
problems to the appropriate supervisor. operator's platform. This may be furnished by Telsmith or by
the owner of the equipment. The operator's platform should
• Before performing inspections or maintenance, always
be positioned so that the operator has a clear view to control
lock out and tag power to the machinery, and to all feed
the feed of material to the equipment. Remote cameras can be
and discharge equipment for the machinery. Warn all
located to assist the viewing of feed points that are obstructed
personnel that the equipment is being serviced. Refer to
from the operator's view. An operator's cabin should be
the Lockout/Tagout section of this chapter for additional
provided in environments where the operator would be
information.
exposed to harmful dust, noise, and bad weather conditions.
• Maintenance inspection procedures are included The operator's platform should be isolated from any structure
throughout this manual. Although maintenance is not that might cause the operator to be exposed to excessive
typically a safety concern, machinery that is regularly vibrations.
maintained and in proper working condition will
Typical installations of Telsmith equipment will include
minimize the occurrence of safety hazards and emergency
service platforms. These may be furnished by Telsmith or by
situations.
the owner of the equipment. Since these platforms are
typically installation specific, Telsmith provides several
EQUIPMENT INSTALLATION SAFETY hazard decals to be located at the time of installation. The
placement of these decals is part of the initial start-up
Equipment Vibration checklist for the particular Telsmith equipment. Refer to
Some Telsmith equipment is designed to vibrate during specific Telsmith operator manual for proper placements.
operation. Vibrations are amplified during the start-up and The construction of any platforms shall conform to MSHA
shut-down cycles. There is a risk of a crushing injury if body and OSHA regulations for the area in which the equipment is
parts become pinched by the motion of the equipment. to be operated.
CAUTION - Be advised to keep hands and body parts away
from the moving equipment to avoid injury. Support structures Operator’s Vantage Point
must be suitably designed to accept these vibrational forces.
The dynamic loads generated by the equipment are • Telsmith suggests that the operator of the equipment
referenced on the installation drawing. should have a clear vantage point to view the flow of
material into the primary sections of large capacity plants
(250 tons per hour or more). This will ensure good control
Foundations and Supports
of material flow into the primary and into downstream
Your Telsmith equipment, along with any supporting components. It will also promote quicker reactions to
structure, must be installed on an adequate and proper problems, such as blockages, resulting in improved
foundation. Consider the following when preparing for the overall efficiency.
installation of the equipment:
• An adequate foundation on a solid footing is required.
The load-bearing capacity of the location for the
machinery must be 2500–3000 lb/ft2. The location should
be as level as possible.

Guarding • If power and control lines are run overhead, allow for
plenty of clearance for vehicle traffic of all sorts. If there
• Quarry management is responsible for the proper
are multiple cables, a cable tray should be used to support
installation and placement of guards to prevent personnel
all lines.
from coming in contact with rotating or moving parts.
• Maintain adequate overhead clearance from power lines
• In addition to the guards supplied with the machinery,
or other obstructions, particularly when planning to use
additional guards and related safety equipment may be
stacking conveyors for stockpiles.
required to comply with OSHA, MSHA and any
applicable local regulations. The proper fabrication, • Be sure that electrical power supplies are located in an
installation and placement of these items is quarry area that will be safe from accidental contact during
management’s responsibility. operation.
• When fabricating guards, refer to MSHA’s Guide to • All Telsmith machinery is designed with electrical
Equipment Guarding. Additional information can also be components of the proper size and voltage.
provided by the safety officer at your worksite.
• Be sure that all connections are in accordance with the
• Never remove guards until the machinery is stopped, National Electric Code (NEC) and any applicable state or
power is locked out and tagged. Be sure that guards are local codes.
properly reinstalled before reconnecting power. Refer to
• NEVER run computer cables in the same conduit as
the Lockout/Tagout section of this chapter for additional
electrical power cables. This will cause interference with
information.
the computer input/output data.
Customer Modifications • Incoming power and utility company transformers should
be located away from the crushing and screening
• Do not modify quarry machinery in any way without prior
equipment and vehicle travelways. Any modifications to
approval from the manufacturer. Such modifications may
these components or to the power supply must be
include (but are not limited to) changing machine speed or
approved in writing by the Telsmith Engineering
direction of rotation, drilling additional holes and welding
Department.
or bolting additional equipment to the machinery.
• All customer modifications to Telsmith machinery must
be approved in writing by the Telsmith Engineering
Department.
Electrical Installation Safety
! WARNING
When installing any electrical equipment, be
sure to completely follow the manufacturer’s
instructions. Failure to observe this precaution
could result in a dangerous electrical shock
hazard.
• Be sure that all electrical equipment is properly grounded.
• Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
• Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power
line across a traffic area, protect the cable with properly
rated bridging.
• Be sure that all auxiliary control panels or power supply
panels can be securely locked out. This type of panel is
mandatary.

MAINTENANCE AND REPAIR SAFETY • Do not tamper with machinery alarm components. Never
attempt to defeat electrical interlocks or to disable
machine protective devices.
! WARNING
Always lockout/tagout power to the machinery Pressurized Systems
and to all feed and discharge equipment before (Hydraulic and Pneumatic)
performing any maintenance or repairs. Warn all
• Adjust, maintain and repair all pressurized systems only
personnel that the machinery is being serviced.
in accordance with the instructions contained in the
manufacturer’s manuals provided with the machinery.
General Precautions
• Never attempt to work on a pressurized system while it is
• To help ensure safe machine operation, use only genuine
pressurized or in operation.
OEM replacement parts that are sold or approved by the
machine’s manufacturer. Use of non-OEM parts may • Before performing maintenance or repairs on any
adversely affect machine operation and could result in a pressurized system:
hazardous situation.
— Cycle the controls through all operating positions to
• Always tighten all fasteners to the proper torque as relieve any trapped pressure.
described in the repair procedures. When torque
— Check that ALL pressure is relieved from the system.
specifications are not listed, use the values in the torque
Pressure gauges must read zero (0) psi.
table at the back of this manual. Refer to Appendix A of
this manual. — Lockout and tag all controls. Be sure electrical power
is properly locked out and tagged.
• Be sure all replacement fasteners are of the proper grade
and specifications. Replace any worn or damaged
fasteners.
Electrical Systems
• Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
instructions in the machinery manufacturer’s manuals.
• Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local
regulations.
• When servicing an electrical system, work with the power
locked out and tagged. Always assume that an electrical
system is live until it has been locked out.
• Always lockout and tag power before removing cables
with quick-disconnect plugs.
• Repair any obviously worn or damaged wires and
connectors.
• Inspect power cables and connections daily for signs of
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three-wire plug or
double insulated. Be sure that all extension cords are
grounded with a three-wire plug.

• Allow time for hot hydraulic oil to cool before performing • Be sure to wear the proper welding shield, welding gloves
any maintenance or repairs. Hot oil can cause burns. and clothing. Do not wear synthetic-fabric clothing or
clothing which could be easily ignited by sparks.
• Wear safety glasses or face shield when working on
pressurized systems. • Always follow all standard safety procedures when
welding. Be sure that all systems are locked out and
• Before loosening fittings or removing components,
tagged out. Provide welding screens to protect other
always recheck that ALL pressure is relieved from the
employees working in the area.
system. Pressure gauges must read zero (0) psi.
• Relieve all hydraulic pressure before welding near
• Never attempt to loosen a hydraulic fitting while a
hydraulic components and lines. Cover hydraulic
hydraulic system is pressurized. Serious personal injury
components to protect them from weld spatter and sparks.
could result.
• Do not weld near flammable liquids or hydraulic oils.
• Never have your face near, or stand directly in front of a
hydraulic line when loosening a fitting, even after system • DO NOT weld lifting eyes or hooks to any components.
pressure has been relieved. Always assume that the line Welding lifting eyes or hooks to components made of
has pressure. manganese, cast iron, ductile iron or other alloyed
materials may fail when being hoisted or moved. If it
• Use a piece of cardboard, not your hand, to check for
becomes absolutely necessary, use a stainless steel or
hydraulic oil leaks. Escaping fluid under pressure can
manganese welding rod. Use extreme caution when lifting
penetrate the skin, resulting in serious personal injury.
or moving these items and keep all personnel clear.
• Clean up any spilled hydraulic oil. Hydraulic oil is
• Never ground the welder so that the electrical power will
extremely slippery, and can be especially dangerous if
flow through bearings, hydraulic components or electrical
spilled on an elevated walkway or platform.
equipment. Serious damage could result.
• Repair any leaks immediately. Always relieve system
• Be sure all compressed gas cylinders are stored upright,
pressure and lockout/tagout power before tightening
chained and capped. Turn off all cylinders when not in
fittings or making repairs.
use.
• Never attempt to adjust pressure relief valves to above the
machinery manufacturer’s recommended settings.
Serious personal injury and/or equipment damage could
result.
• Do not operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always replace
any defective components immediately.
• Never place hands on hydraulic cylinder rods while
equipment is in operation.
• Refer to manufacturer’s instructions when recharging
hydraulic accumulators or checking accumulator
pressure. Allow only trained hydraulic system technicians
to depressurize, recharge or repair hydraulic
accumulators.
Welding, Cutting or Grinding on Machinery

• Be sure to provide adequate ventilation when welding,
cutting or grinding inside enclosed areas to prevent the
buildup of hazardous fumes or dust. Special concern
should be exercised when welding, cutting or grinding
chromium, manganese, cadmium, copper, cobalt, lead
and nickel, as these materials are considered to be
potentially carcinogenic.

Clearing Jammed Material Disposal of Excess Fuels, Lubricants and

• If material becomes jammed in the machinery: Liquids
— Immediately stop the machinery. Quarry personnel are responsible for the proper disposal of
unused fuels, used lubricating oils, used hydraulic oils, and
— Lockout/tagout power. Warn others that the other toxic materials. DO NOT dispose of these materials in
machinery is being serviced. an unapproved manner. Follow all applicable federal, state
— Follow the instructions in the operation and and local regulations.
maintenance manual of the affected equipment.
Flammable and Combustible Liquids
• To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in • Store flammable liquids in a safe place, away from quarry
operation. machinery and personnel. Use approved safety containers
and be sure that they are clearly marked. Containers must
• Always remove all jammed material before restarting the be covered when not in use.
machinery. To prevent damage, never attempt to restart a
stalled machine without first removing the jammed • Keep flammable liquids away from sparks, open flame,
material. and other ignition sources. Do not smoke around
flammable liquids. Always obey posted “no smoking”
• Never use dynamite or other explosives to clear jams. signs.
Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur. • Be familiar with the locations of fire extinguishers
throughout the quarry. Be sure they remain accessible at
all times, and are not blocked by obstructions.
Hazardous Materials
• Do not use gasoline or other flammable liquids to clean
• Be aware of potentially hazardous chemicals or materials.
tools or parts. Use only approved non-flammable
Such items can be harmful if they are improperly used,
solvents.
stored, mixed or transported, or if they are inhaled,
swallowed or allowed to contact the skin. • Always shut off engines before refueling. Ground fuel
spout against the filler neck to prevent static electricity.
• Consult your employer’s hazard communications plan for
Never smoke while refueling.
instructions regarding the proper handling and use of
hazardous materials. Read and understand the labels • Use only approved safety containers for storing and
attached to the product containers. Always follow the transporting small quantities of flammable liquids. Keep
instructions carefully. containers covered when not in use.
• Consult the manufacturer’s material safety data sheet
(MSDS) for potential hazards and appropriate medical
procedures should an accident occur.
• Store hazardous materials only in approved containers. Be
sure containers are clearly labeled.
• To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods
for handling mineral oils.
• Always wear suitable protective clothing when handling
hydraulic oil.
• Be sure protective clothing and proper washup facilities
are available to all personnel that may come in contact
with mineral-based hydraulic oils.
• Always dispose of used rags or paper towels in the correct
and safe manner.

HOISTING AND HANDLING SAFETY Forming Wire Rope Eyes

When forming eyes in wire ropes, use the following method:
General Precautions
• Use the correct size thimble as recommended by the
• Do not allow personnel to work or walk under loads supplier for the wire rope being used. DO NOT use under-
supported by a crane or hoist. or over-sized thimbles.
• Use appropriate lifting devices to secure the load to the • Use the correct size and number of U-bolt/saddle clamps
crane. See the following paragraphs of this section for to fasten the wire rope dead end to the live side of the wire
additional information. rope. Orient the saddle so it sits against the live side of the
• Use the correct lifting hooks to support the load. rope. DO NOT place the U-bolt against the live side of the
wire rope, as this will crush and deform the wire rope.
• Use extreme caution when operating a crane near power
lines or electrical equipment.
Connecting Wire Ropes
• Do not exceed the crane’s rated load capacity. Always When clamping or connecting two separate pieces of wire
include the weight of the hook block, slings, chains, rope together use the following method:
spreader bars and any additional equipment when
determining the maximum load that can be safely lifted. • Lay the two pieces of wire rope side by side with the spiral
of the strands facing or turning in the same direction.
Wire Rope • Have your supplier determine the number of U-bolt/
Wire rope requires careful use, handling and maintenance to saddle clamps required for your size of wire rope.
ensure long life and safe operation. Always observe the Normally, one complete clamp can carry approximately
following precautions. 75–80% of the wire rope capacity.
• Be sure to use the correct size wire rope for the • Install the clamps so that the saddle portion is alternated
application. from one side to the other.
• Be sure wire ropes are inspected regularly following the

manufacturer’s guidelines. Maintain an inspection log.
• When storing wire rope, follow the manufacturer’s
recommendations for applying a protective coating to the
wire ropes.
• Avoid sudden loading in cold weather. Never use frozen
wire rope in weather below 32°F (0°C).
• Do not use wire rope around sharp corners or edges that
may cause a cut or deformation of the wire rope.
• Use suitable padding to protect wire rope from sharp
corners or edges.
• Avoid dragging wire rope underneath loads or over
obstacles, as this may cause damage to the wire rope.
• Never use wire rope that is cut, badly kinked, frayed or
crushed.
• Avoid reverse bends.
• Be sure rope ends are properly sized.
• Use appropriate sized thimbles in eye fittings at all times.
NEVER attempt to use an undersized thimble in forming
a wire rope eye.
• Follow the manufacturer’s instructions for lubrication if
using wire rope for lifting purposes.

Chains • Wet or frozen slings should not be used until thoroughly

dried. Have supplier inspect sling before using.
Chains require careful use, handling and maintenance to
ensure long life and safe operation.
TRANSPORTATION SAFETY
• Be sure to use the correct size chain for the application.
• Be sure chains are inspected regularly following the General Precautions
manufacturer’s guidelines. Maintain an inspection log. • Be sure that the machinery or equipment is properly
• Avoid sudden or shock loading. DO NOT jerk load secured so that it cannot vibrate or move during transport.
upright or allow load to fall over if chains have too much Remove any dirt, stones or other loose material from the
slack. machinery.
• DO NOT use chains around sharp corners or edges that • Install shipping brackets, wood blocking or other
may damage chain. shipping materials as directed in the machinery
manufacturer’s manuals. Perform any shipment
• Use suitable padding to protect the chain from sharp preparation procedures as indicated in the manuals.
corners or edges.
• Plan your route carefully. Know the clearance height of
• Avoid dragging the chain under loads or over obstacles, as the machinery. Be aware of bridges, power lines and steep
this may cause damage to the chain. or uneven grades. Be aware of any other conditions which
• Always place chain hooks over links with the hook point may present hazards or obstructions.
facing downwards. • Be sure that all tractor-trailer components are working
• Inspect chains for wear. Refer to manufacturer’s and in good condition. Test all systems (brakes, steering,
recommendations for replacement. lights, etc.) for proper operation and/or adjustment before
beginning the move. Check air pressure in all tires and
• Be sure all connections between chain sections are replace any tires that are worn or damaged.
completed with properly sized hardware and lifting
hooks. • After the machinery has been transported, block the tires
if the trailer will remain stationary for an extended period
• When storing chains, follow the manufacturer’s of time.
recommendations for applying a protective coating to the
chains.
MAINTENANCE INSPECTIONS
! CAUTION • Routine maintenance inspections such as lubrication can
often be conducted when performing a safety inspection.
Always follow proper rigging procedures as This will help provide a good service routine and increase
provided by the chain manufacturer. The angle of the efficiency of your operation.
rigging may decrease the rated lifting capacity.
Fiber or Synthetic Slings

Slings require careful use, handling and maintenance to
ensure long life and safe operation.
• Be sure slings are rated or coded for the hitch or
application.
• Be sure slings are inspected regularly following the
manufacturer’s guidelines. Maintain an inspection log.
• DO NOT use fiber or synthetic slings in temperatures
below 32°F (0°C) or temperatures exceeding 150°F
(65.5°C).
• Avoid sudden or shock loading (DO NOT jerk load
upright).
• Keep slings clean and free of solvents, oils and grease.

SAFETY LABELS It should be mentioned here that the ANSI Z535.4-2002

Standards are voluntary standards – they are not a legal
General requirement. However, from a legal point of view, product
manufacturers have the legal “duty to warn” about hazards
Each piece of equipment manufactured by Telsmith, Inc., has associated with the use or maintenance of their products.
undergone a Safety Audit to determine those areas that may
create a potential hazard. These audits were done under the To provide a comprehensive Safety Label, safety labels use
guidelines set forth by the ANSI Z535.4-2002 Standards, EN the “Harmonized” format. The Telsmith “Harmonized”
292-2 European Standards and ISO 3864 Part 2 International format uses the ISO Symbol in a center panel along with
Standards. Hazard audits performed are on file at our English text in the left side panel and the text translation for
facilities. the country of operation in the right side panel of the label.
Where possible, potential hazards have been designed out of To promote a better understanding of the Safety Labels
the equipment. However, when it is impractical to design out specifically designed and used by Telsmith, the following
a potential hazard Telsmith, Inc., applies various safety labels outlines the design of Safety Labels to meet or exceed the
to equipment manufactured to warn of the potential hazard. ANSI Z535.4-2002 and the ISO 3864 Part 2 Standards.
See Figure 1-3 to better understand the parts of a Safety
Types of Safety Labels Label.
Since Telsmith, Inc., furnishes equipment worldwide, Safety
Labels provided comply with the ANSI Z535.4-2002 and the
International ISO 3864 Part 2 Standards.
B C
A
E
H I
F G
Figure 1–3. Safety Label

A – Safety Alert Symbol D – Consequence of Interaction with Hazard G – ISO 3864-2 Symbol
B – Signal Word in Panel E – How to Avoid the Hazard H – Text Panel – Country of Operation
C – Nature of Hazard F – Text Panel – English I – Label Part Number for Ordering

A. “SAFETY ALERT SYMBOL”

This symbol is an exclamation mark enclosed in a triangle. It
is placed next to the Signal Word in the Panel and indicates
that a possible personal (human) injury hazard exists.
B. “SIGNAL WORD in PANEL”

The Signal Words for product Safety Labels are DANGER,
WARNING, CAUTION, and NOTICE. These words call
attention to the Safety Label and designate a level of hazard
seriousness. (ANSI 4.13 Standard.)
• ANSI 4.13.1 DANGER: Indicates an imminently
hazardous situation which, if not avoided, will result in
death or serious injury. The Signal Word is to be limited
to the most extreme situations.
• ANSI 4.13.2 WARNING: Indicates a potentially
hazardous situation which, if not avoided, could result in
• ANSI 4.13.3 CAUTION: Indicates a potentially
hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert
against unsafe practices.
• ANSI Z535.2 NOTICE: Indicates potential equipment
damage may occur if the Safety Label is ignored when
performing maintenance, repair or servicing of the
equipment.
NOTE:
When the Signal Word “NOTICE” is used on a Safety
Label the Safety Alert Symbol is removed from the
panel.
It is the responsibility of the quarry personnel to replace any
worn or illegible labels. Contact the Telsmith Parts
Department for replacement labels.

NOTES

Chapter 2
Features and Specifications
CONTENTS
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
MAJOR FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
DESIGN & CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MOUNTING ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
EXTERNAL DIMENSIONS DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

EXTERNAL DIMENSIONS CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Features and Specifications Operation and Maintenance
DESCRIPTION DESIGN & CONSTRUCTION

The Telsmith Crusher is a cone type crusher available in both • 100% fabricated, stress-relieved main frame is carefully
S (standard) and FC (fine-crush) configurations. The S heat treated and features heavy steel construction. Upper
configuration is designed for coarse and intermediate frame has fully-machined buttress threads to ensure
crushing, while the FC is intended for secondary and tertiary proper alignment with the main frame.
crushing.
• Common support bowl design for both S and FC
configurations allows the crushing chamber profile to be
MAJOR FEATURES easily changed when necessary.
• Cam and lever crushing action provides maximum • Replaceable steel shields provide added protection for the
efficiency and distributes crushing loads over a large crusher frame arms and countershaft box housing. Interior
bearing area. The unrestricted feed opening allows easier surfaces of the crusher main frame are steel-lined for
passage of large or slabby material. added durability.
• When required, the hydraulic relief system automatically • Labyrinth type seals provide a positive barrier to
releases upper frame clamping pressure to allow passage contaminants, keeping dust and moisture away from
of tramp iron and other uncrushables. If needed, the entire bearings and other internal parts. Fitted piston rings
upper frame can be hydraulically raised to safely clear control internal oil flow and help prevent oil leakage.
large obstructions and jammed material.
• Balanced rotary seal ring helps ensure smooth crusher
• Power rotation allows quick push-button adjustment of operation.
the discharge opening, even while crushing is in progress.
This feature also allows high speed extraction of the • Durable bronze sleeves withstand high crushing loads and
support bowl assembly when necessary for liner severe operating conditions. Cylindrically-ground tapered
replacement or other maintenance activities. main shaft assures precise clearances.
• An automatic anti-spin device (optional equipment) • Hardened steel countershaft is supported by tapered roller
prevents the head from turning with the eccentric when bearings. The entire countershaft box is removable as a
the crushing chamber is underfilled or empty. This feature single assembly for easier servicing.
helps prevent excessive liner wear during low feed rate
conditions.
• The external oil lubrication system provides a continuous
supply of filtered oil to the crusher’s internal parts. The
electric oil pump allows warm oil to be circulated through
the crusher before start-up.
• A shut-down alarm immediately stops the crusher in the
event of low oil pressure, low oil flow or high oil
temperature.

Operation and Maintenance Features and Specifications
OPTIONAL EQUIPMENT
• Electric motor and controls
• Diesel engine
• V-Belt drive and guard
• Air-oil cooler (oil system)
• Additional oil immersion heaters
• Anti-spin unit
• Power rotator
• TRAC10 Automation Control
MOUNTING ARRANGEMENT
The cone crusher is available as a stationary unit, or as part of
a complete Telsmith portable crushing plant.
If your crusher is mounted on a portable plant chassis:
• Refer to the Telsmith Portable Plant Installation and
Maintenance Manual for general plant installation and
set-up instructions.
• Refer to the Plant Assembly Drawing for the external
dimensions of your portable plant.
• Refer to the Oil System Assembly Drawing for a diagram
of the oil lubrication system piping and components.
• Refer to any additional engineering drawings that have
been provided separately with this manual.
Some portable plants may include additional Telsmith
equipment, such as vibrating screens or feeders. Separate
operation and maintenance manuals have been provided for
this equipment. Refer to these manuals for installation and
start-up procedures.

EXTERNAL DIMENSIONS DRAWING
E
F
G
H
B
C
D
L M
S
R
Q
U N
O
OPTIONAL ANTI-SPIN
ASSEMBLY T P
STANDARD
ASSEMBLY

EXTERNAL DIMENSIONS CHART
DIMENSIONS 38 44 52 57 68
A 62.00 (157.48) 68.00 (172.72) 76.00 (193.04) 92.00 (233.68) 113.50 (288.29)
B 31.00 (78.74) 34.00 (86.36) 38.00 (96.52) 46.00 (116.84) 56.75 (144.15)
C 29.50 (74.93) 30.00 (76.20) 35.00 (88.90) 43.50 (110.49) 48.00 (121.92)
D 21.00 (53.34) 20.50 (52.07) 26.00 (66.04) 28.50 (72.39) 33.50 (85.09)
E 62.00 (157.48) 69.75 (177.17) 76.00 (193.04) 92.00 (233.68) 113.50 (288.29)
F 31.00 (78.74) 34.88 (88.58) 38.00 (96.52) 46.00 (116.84) 56.75 (144.15)
G 29.50 (74.93) 30.00 (76.20) 35.00 (88.90) 43.50 (110.49) 48.00 (121.92)
H 21.00 (53.34) 20.50 (52.07) 26.00 (66.04) 28.50 (72.39) 33.50 (85.09)
I 1.13 (2.86) 1.13 (2.86) 1.38 (3.51) 1.63 (4.14) 2.00 (5.08)
J 34.00 (86.36) 35.94 (91.28) 44.81 (113.82) 48.00 (121.92) 48.50 (123.19)
66.57—72.07 66.88—72.38 75.50—81.00 82.31—87.81 92.43—97.93

K
(169.09—183.06) (169.88—183.85) (191.77—205.74) (209.07—223.04) (234.77—248.74)
L 18.74 (47.60) 18.74 (47.60) 21.91 (55.65) 21.61 (54.89) 28.35 (72.01)
M 15.70 (39.88) 15.70 (39.88) 18.76 (47.65) 18.45 (46.86) 24.45 (62.10)
N 11.94 (30.33) 11.94 (30.33) 13.96 (35.46) 19.81 (50.32) 19.86 (50.44)
O 53.63 (136.22) 53.50 (135.89) 59.25 (150.50) 66.63 (169.24) 80.00 (203.20)
P 58.31 (148.11) 58.19 (147.80) 65.06 (165.25) 72.44 (184.00) 86.94 (220.83)
Q 3.5° 3.5° 3.4° 3.5° 3.4°
R 29.44 (74.78) 29.44 (74.78) 32.51 (82.58) 32.19 (81.76) 36.95 (93.85)
S 19.33 (49.10) 19.33 (49.10) 22.39 (56.87) 22.08 (56.08) 26.84 (68.17)
T 10.64 (27.03) 10.64 (27.03) 10.64 (27.03) 10.64 (27.03) 10.76 (27.33)
U 4.0° 4.0° 4.0° 4.0° 4.0°

WEIGHTS
GYRASPHERE WEIGHTS IN POUNDS (KILOGRAMS)
Oil
Oil Oil
Lubrication
Model Crusher, Lubrication Lubrication
Crusher, Crusher, System with Hydraulic Guard,
Complete Flywheel System with System with
Lower Half Upper Half Water- and Power Unit Standard V-
and Sheave Water-Oil Air-Oil
* ** Air-Oil † Belt Drive
Assembled Cooler Cooler
Coolers
*** ***
***
38S 27520 16120 11400 320 3000 3200 3300 900 520
(12483) (7312) (5171) (145) (1360) (1451) (1496) (408) (236)
38S
with 28340 16520 1400 320 3000 3200 3300 900 520
ASU (12854) (7493) (635) (145) (1360) (1451) (1496) (408) (236)
38FC 27620 16120 1500 320 3000 3200 3300 900 520
(12528) (7311) (680) (145) (1360) (1451) (1496) (408) (236)
38FC
with 28440 16520 1500 320 3000 3200 3300 900 520
ASU (12900) (7493) (680) (145) (1360) (1451) (1496) (408) (236)
44S 32982 20800 12140 320 1380 1880 3300 600 520
(14960) (9435) (5507) (145) (626) (853) (1496) (272) (236)
44S
with 33369 21187 12140 320 1380 1880 3300 600 520
ASU (15136) (9610) (5507) (145) (626) (853) (1496) (272) (236)
44FC 33382 21200 12140 320 1380 1880 3300 600 520
(15142) (9616) (5507) (145) (626) (853) (1496) (272) (236)
44FC
with 33769 21587 12140 320 1380 1880 3300 600 520
ASU (15317) (9792) (5507) (145) (626) (853) (1496) (272) (236)
52S 48778 31961 16740 540 1880 2465 2520 1280 778
(22125) (14497) (7593) (245) (853) (1118) (1143) (581) (353)
52S
with 49372 32555 16740 540 1880 2465 2520 1280 778
ASU (22395) (14766) (7593) (245) (853) (1118) (1143) (581) (353)
52FC 48876 32059 16740 540 1880 2465 2520 1280 778
(22170) (14542) (7593) (245) (853) (1118) (1143) (581) (353)
52FC
with 49470 32653 16740 540 1880 2465 2520 1280 778
ASU (22439) (14811) (7593) (245) (853) (1118) (1143) (581) (353)
* ASU - Anti Spin Unit

GYRASPHERE WEIGHTS IN POUNDS (KILOGRAMS)
Oil
Oil Oil
Lubrication
Crusher, Lubrication Lubrication
Model Crusher, Crusher, System with Hydraulic Guard,
Complete Flywheel System with System with
Lower Half Upper Half Water- and Power Unit Standard V-
and Sheave Water-Oil Air-Oil
* ** Air-Oil † Belt Drive
Assembled Cooler Cooler
Coolers
*** ***
***
57S 73562 44460 29102 750 1880 2680 2700 1280 499
(33367) (20167) (13200) (340) (853) (1216) (1225) (581) (266)
57S
with 74093 44991 29102 750 1880 2680 2700 1280 499
ASU (33608) (20181) (13200) (340) (853) (1216) (1225) (581) (266)
57FC 73962 44860 29102 750 1880 2680 2700 1280 499
(33549) (20348) (13200) (340) (853) (1216) (1225) (581) (266)
57FC
with 74493 45391 29102 750 1880 2680 2700 1280 499
ASU (33789) (20589) (13200) (340) (853) (1216) (1225) (581) (266)
68S 106668 66208 40460 870 2250 3430 3480 1560 506
(48383) (30031) (18352) (395) (1021) (1556) (1578) (708) (230)
68S
with 107111 66651 40460 870 2250 3430 3480 1560 506
ASU (48584) (30232) (18352) (395) (1021) (1556) (1578) (708) (230)
68FC 108268 66208 42340 870 2250 3430 3480 1560 506
(49109) (30031) (19205) (395) (1021) (1556) (1578) (708) (230)
68FC
with 108711 66651 42340 870 2250 3430 3480 1560 506
ASU (49310) (30232) (19205) (395) (1021) (1556) (1578) (708) (230)
Notes:
* Crusher lower half - Total weight of the main (lower) frame and all internal components. Includes weight of the hydraulic
relief cylinders, flywheel sheave and anti-spin unit (ASU) if equipped. Does NOT include weight of the support structure,
drive motor and motor base
** Crusher upper half - Total weight of the upper frame and all internal components. Includes weight of the hydraulic locking
cylinders, power rotator assemblies, and upper frame mounting bolts.
*** Weight with oil tank drained. (For all models: Add 825 lbs. (374 KG) if filled.)
† Weight with hydraulic reservoir drained. (For Models 38 and 44: Add 220 lbs. (100 KG) if filled. For Models 52, 57 and 68:
Add 440 lbs. (200KG) if filled.)
Important: All weights shown are estimated and may vary by +/- 5 percent due to fabrication variables, optional equipment
or custom engineering. When available, always refer to the bill of lading or packing list for actual weights.
* ASU - Anti Spin Unit

NOTES

Chapter 3
Crusher Installation
CONTENTS
Page
RECEIVING THE SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Shipment Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection & Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Reporting Damaged or Missing Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CRUSHER LIFTING & HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
CRUSHER FOUNDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CLEARANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Mounting the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pouring Concrete Grout
(Concrete Foundation Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
UPPER FRAME INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
FEED ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
DISCHARGE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
INSTALLING THE OIL LUBRICATION SYSTEM AND HYDRAULIC POWER UNIT 3-13
MOTOR & DRIVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Electric Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
V-Belt Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Countershaft Speed & Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
V-Belt Drive Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
DIESEL ENGINE PREPARATION

(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
NEW CRUSHER BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
INITIAL START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Crusher Installation Operation and Maintenance
RECEIVING THE SHIPMENT Inspection & Unloading

1. Always use proper lifting and handing procedures
Shipment Details when unloading and unpacking the shipment. To avoid
The upper frame is pre-installed prior to shipment for damage, follow the instructions in Crusher Lifting And
most crushers. However, it may be shipped separately Handling section of this chapter.
if necessary to comply with weight or space restrictions. 2. Compare the total number of pieces received in the
For additional information, refer to the Upper Frame shipment against the quantity shown on the bill of
Installation in this chapter. lading. Check for any missing pieces.
For stationary-mounted crushers, the oil lubrication 3. Check the crusher and its subassemblies for
system and hydraulic power unit are shipped separately obvious signs of damage.
from the crusher. These subassemblies must be
installed and connected after the crusher is mounted on 4. Inspect the shipping crates. Be sure they are not
its foundation. crushed or broken open.
If the crusher is mounted on a Telsmith portable plant, 5. Remove all parts from the shipping crates and check
the oil lubrication system and hydraulic power unit are them against the packing list. Make a note of any
normally pre-installed on the plant chassis. However, damaged or missing items.
some additional wiring and final assembly may be
required. Reporting Damaged or Missing Items
Tools and loose parts are packed inside wooden crates Missing items or non-concealed damage must be noted
or fastened to pallets. The exact items included in each in writing on the delivery receipt when the shipment is
shipment will vary, depending on the crusher’s level of delivered. The carrier will have the right to reject any
pre-assembly. future damage claims if this is not done.
Refer to the bill of lading and packing list for a complete

description of the components and subassemblies
supplied with your crusher. See Figure 3–1.
CHECK THE ENTIRE SHIPMENT FOR MISSING OR

DAMAGED ITEMS
REFER TO THE BILL OF LADING AND PACKING LIST

WHEN UNLOADING THE SHIPMENT
Figure 3–4. Unpacking and Inspecting the Shipment.

Operation and Maintenance Crusher Installation
Report any missing items or non-concealed shipping

damage as follows:
1. Provide a brief description of the missing or
damaged items in writing on the delivery receipt. Make
a copy of the delivery receipt for your records.
2. Notify the carrier immediately and request an
inspection by an authorized representative. Save any
damaged items or shipping materials so that they are
available for examination during the inspection.
3. File a damage claim with the carrier immediately
after the inspection.
IMPORTANT: A
Immediately report any concealed shipping damage or
parts shortages to the Telsmith Service Department or
your local Telsmith dealer.
CRUSHER LIFTING AND HANDLING
! WARNING Figure 3–5. Lifting the Crusher.

Do not allow personnel under the crusher while A – Main Frame Lifting Lug
it is being supported by a crane or other lifting
• NEVER attempt to lift the crusher using the upper
device. Always use suitable rigging and hoisting
frame lifting lugs. These lugs are not designed to lift
equipment to stabilize and lift heavy objects.
the entire crusher. Serious damage could result.
Lifting heavy components with inadequate
hoisting apparatus can result in serious injury or • NEVER place slings around the flywheel sheave or
death. the countershaft. These components should never
be used as lifting points.
1. Read and understand the general hoisting and
handling safety precautions contained in Chapter 1. • Handle the crusher with care. Ensure that it remains
upright and evenly supported at all times. Rough or
2. Refer to the bill of lading or packing list for the actual
careless handling can cause serious damage. Never
weight of the complete upper frame assembly. If these
allow the crusher to hit other objects or drop on the
documents are not available, refer to Chapter 2 for
ground.
estimated weights. Be sure that the lifting device and all
other lifting equipment is of adequate capacity to • To prevent accidental damage to the underside of
support the entire load being lifted. the crusher, always leave hardwood blocking in-
place until the crusher is ready to be installed on its
3. Lift the crusher by the main frame lifting lugs only,
foundation.
making sure that it is evenly supported. See Figure 3–
2. Also note the following precautions:
IMPORTANT:
Improper lifting procedures can result in permanent
damage to the crusher and its components. Such
damage is not covered under warranty!

CRUSHER FOUNDATION CLEARANCE REQUIREMENTS

Refer to the instructions in the General Arrangement Note the following guidelines when planning the crusher
Drawing (provided separately with this manual) when installation. Refer to Chapter 2 for crusher External
creating the foundation and support structure for a Dimensions.
stationary-mounted crusher. Also note the following
• Allow adequate room beside the crusher for
recommendations and requirements:
walkways and service platforms. Observe all federal,
• Mount the crusher on a solid foundation of level, state and local regulations when designing and
solid rock or a compacted aggregate base. Do not constructing such structures.
locate the foundation on sand, unstable soil, or
• Allow adequate room above the crusher for
anywhere that flooding is likely to occur. Where fill of
hydraulic relief. The upper frame will rise up to 5-1/2
any kind has been used, the foundation must extend
inches when uncrushable material enters the
through the fill to a solid sub-surface.
crushing chamber. It must never contact any
• Sub-soil conditions should be investigated by test chutework or structural steel, even when fully raised.
boring. Core samples may reveal underground
• Allow adequate room above the crusher for head
water or hidden layers of loose sand. Do not locate
and shaft removal. Any structures or chutes
the foundation in areas where these conditions are
mounted above the crusher must be designed for
present.
easy removability when repairs are necessary.
• The foundation must be of adequate load bearing
• Allow adequate room beside the flywheel sheave to
ability to support the combined weight of the crusher,
permit removal of the sheave and countershaft box
its suppor t structure and the mater ial being
when repairs are necessary.
processed. The foundation must also be capable of
withstanding the forces generated during crushing. • Allow adequate room beside the V-belt drive for
routine inspection and maintenance. All V-belt drive
• The support structure must be firmly anchored to the
components must be easily accessible when the
foundation and sufficiently braced to minimize
drive guard is removed.
vibration and swaying.
• Allow adequate room around the oil lubrication
• Follow any special instructions that have been
system and the hydraulic power unit. All service
communicated to you by Telsmith engineering or
points must be easily accessible for routine
service personnel.
inspection, lubrication and maintenance activities.
• Contact your local Telsmith dealer or the Telsmith
Service Department if you have any questions
regarding foundation design or installation.

Mounting the Crusher Pouring Concrete Grout

• The crusher must be horizontally and vertically level (Concrete Foundation Only)
when mounted. Damage to cr usher inter nal 1. Clean the foundation surfaces where the grout will
components may result if the crusher is not be poured. Leave these surfaces rough. Lightly oil the
completely level. See Figure 3–3. underside of the crusher mounting flanges to prevent
• Steel foundation only: Install steel leveling shims adhesion of the grout to the crusher.
as required. Then tighten the crusher mounting nuts 2. Place steel leveling shims (as required) around the
to firmly secure the crusher to the foundation. foundation bolts. The shims must be high enough to
G r o ut i n g i s n o r m a l l y n o t r e q u i r e d fo r s t e e l allow for a nominal grout thickness of approximately 1/
foundations. 2 to 3/4 inch (13 to 19 mm) at each corner of the
• Concrete foundation only: Install steel leveling crusher.
shims as required. Then pour concrete grout 3. After lowering the crusher onto the shims, check
between the crusher mounting flanges and the crusher levelness as shown in If necessary, install or
foundation. Tighten the crusher mounting nuts after remove shims (as required) around the foundation bolts
the grout has hardened. For additional instructions, until the crusher is completely level. See Figure 3–3.
refer to the following procedure.
NOTE:
Use a high impact type grout which contains a non-
Crusher must be horizontally and vertically level
(Check in both places as shown) shrink additive. Be sure to follow manufacturer’s
instructions when handling and pouring grout.
4. Use wooden forms to contain the grout during
A pouring. Thoroughly wax or grease the forms to prevent
them from sticking to the grout. Seal all joints and
seams to prevent grout leakage during pouring.
5. Wait for grout to harden before securing the crusher
to the foundation. In most cases, full hardening will
occur approximately 6 hours after pouring.
6. After the grout has hardened, verify that the crusher
remains completely level. Then tighten the mounting
nuts to firmly secure the crusher to its foundation.
Figure 3–6. Checking Crusher Level

A – Level

UPPER FRAME INSTALLATION

Coat the entire
If removed for shipping purposes, install the upper machined surface. Apply grease
frame as described in the following procedure. to seat.
1. Using an appropriate cleaning solvent, completely
remove the rust preventative coating from the machined Moly
seats of the upper and main frames. See Figure 3–4. EP-2
IMPORTANT:
Read and understand manufacturer’s instructions and
safety precautions before using solvent. Wear
appropriate personal protective equipment and
clothing.
Moly Based EP-2 Grease Specifications

(Aluminum Complex with
Molybdenum Disulfide)
Work Penetration 265/295
Dropping Point °F 510
Remove rust
Rust Prevention (ASTM D -1743) Pass
preventative
c o a t i n g f ro m Corrosion Prevention (ASTM D -1261) Pass
seats. Oxidation Stability (ASTM D - 942)
Oxygen Absorption (PSI) After:
100 Hours <3
200 Hours <4
300 Hours <5
Oil Viscosity, SUS @ 100 °F 1000
B
Extreme Pressure Performance
Timken OK Load (lbs) 65
Figure 3–7. Removing Rust Preventative Four Ball Weld Point 800
Wear Scar 0.51 mm
A – Upper Frame B – Main Frame
Type of Soap Aluminum
2. Carefully inspect both machined seats. Be sure they Complex
are free of any dust. Operating Temperature 0 to 450 °F
MoS2 % by Weight 3.0
3. Apply a generous coating of Moly-based EP-2
grease completely around the main frame seat. See
Figure 3–5. Figure 3–8. Main Frame Seat Lubrication
4. If present, remove the protective plastic coverings

from around the relief cylinder couplings.

NOTE: This power C

NOTE: This power
r o t a t o r i s N OT r o t a t o r i s N OT
used on Model 38 used on Model 44
Crushers. Crushers.
Note: Refer to the “Sectional

Assembly” installation drawing
(provided separately) for power
rotator position.
Figure 3–9. Installing the Upper Frame—Standard Mounting

A – Upper Frame B – Thrust Pin Bushing C – Thrust Pin
! WARNING NOTE:
Use properly rated lifting device and equipment. The standard power rotator position is shown on the
Lifting heavy components with inadequate Sectional Assembly installation drawing. If needed the
equipment can damage machinery and may upper frame may be mounted 120 degrees to the right
result in serious personal injury or death. Refer or left of the standard location, to provide sufficient
to Chapter 2 for weights. power rotator clearance.
5. Attach an appropriate lifting device and cables to the 6. As the upper frame remains suspended, slowly
three upper frame lifting lugs. Adjust the cables so that rotate upper frame until the thrust pin bushings are
the upper frame will be evenly supported. Carefully lift aligned with the thrust pins.
the upper frame and suspend it several feet above the
main frame. See Figure 3–6.

Use NGLI #2 grease

(Minimum 3% Moly).
Pack grease between thrust
pin and bushing.
A
C
MODEL 38 MODELS 44, 52, 57

AND 68
Figure 3–10. Thrust Pins

A – Thrust Pin B – Bushing C – Dust Cap
7. Align the thrust pin bushings with the thrust pins.

Slowly lower the upper frame onto the main frame. See
Figure 3–7.
8. On Model 44, 52, 57 and 68 Crushers: Unscrew
the dust cap above each thrust pin. Pack the area
around the thrust pins with grease. Reinstall dust caps
after greasing. Refer to Figure 3–7.

Apply anti-sieze to
bolts.
MODELS 44, 52, 57
MODEL 38
AND 68
Figure 3–11. Exploded View, Upper Frame Mounting Bolt

A–Mounting Bolts B – Flat washer C – Upper Frame D – Cylinder Coupling E – Relief Cylinder
9. Loosely install each mounting bolt as follows. See E. Hand install the mounting bolt at least two turns,
Figure 3–8. then pull up on the bolt to verify that it is properly
engaged. Be sure that the bolt is not cross-
A. Apply anti-seize compound to the mounting bolt
threaded.
threads.
B. Install a flat washer under the bolt head.
NOTE:
Flat Washer must be installed under bolt head to
prevent bottoming out the coupling.
C. Position the mounting bolt through the bolt hole in
the upper frame.
D. Align the threaded bolt end with the cylinder
coupling. Carefully engage the threads.

12.After tightening the mounting bolts, visually check

NOTE: that the top surface of each cylinder coupling is
Bolt tightening will be easier if the relief cylinders are completely flush with the underside of the upper frame
extended a small amount as described in step 11. (no gap). If a gap is present, an incorrect length bolt may
However, if the hydraulic power unit is not available, have been used, or the flat washer is not installed
skip step 10 and go on to step 11. beneath the head of the bolt (Fig. 3-10). If bolt length is
too long, or the washer is missing, the bolt may bottom
in the cylinder rod coupling causing it to bind. This could
! CAUTION also result in the cylinder coupling not being snug
Cylinders will extend during the next step. To against the upper frame. Check that the cylinder rod
prevent injury, keep hands and fingers away coupling is free to swivel, which indicates the bolt has
from the area between the upper frame and the not bottomed in the coupling.
cylinder couplings.
10.Activate the hydraulic clearing function. Extend the
relief cylinders a small amount, until all cylinder
couplings are just touching the underside of the upper
frame. Refer to Chapter 8 for hydraulic system
operating instructions.
A
B
C
Apply NLGI-2 (3% moly

minimum) grease on a
daily basis to cylinder
coupler grease fittings.
Figure 3–12. Installing Upper Frame Mounting Bolts
A – Impact B – Cylinder C – Open End
Wrench Coupler Wrench Figure 3–13. Checking Cylinder Rod Coupling
Installation
11.Using an impact wrench, tighten the mounting bolts
until snug. During tightening, have an assistant hold the
cylinder coupling in place with an open-ended wrench to A – Bolt B – Washer C – Grease Fitting
D – Cylinder Rod
prevent it from turning. See Figure 3–9. Coupling

13.Install brass plugs and setscrews into the small 14.Rotate the cylinder couplings so that the grease
threaded holes of each cylinder coupling. Tighten the fittings face outward. At each coupling, apply grease
setscrews until snug. Apply anti-seize compound to with a hand grease gun until a small amount of purged
setscrews as installed. See Figure 3–11. grease is visible. See Figure 3–12.
15.Activate the hydraulic relief function. Check for any
A A hydraulic oil leaks or other obvious problems. Refer to
Chapter 8 for hydraulic system operating instructions.
B
C
Use NGLI #2 grease

(Minimum 3% Moly).
Apply anti-sieze
compound to
setscrews. Figure 3–15. Greasing the Cylinder Coupling
Figure 3–14. Installing Setscrews

A – Brass Plug B – Setscrew C – Cylinder Coupler

FEED ARRANGEMENT
The crusher feeding device (screen, conveyor, etc.) Feed evenly
distributed 360°
must be capable of keeping the crushing chamber filled
around the
with a sufficient amount of material at all times. See shaft nut.
Figure 3–13.
Use feed box
Gyrasphere cone crushers require a choke feed, in where possible
which the material level remains at or above the top of
the concave ring.
B
An even distribution of material 360 degrees around the
crushing chamber will result in higher production of the A
desired product size. C
Observe the following guidelines when planning the
feed arrangement and installing feeding devices:
• Position the conveyor, feed chute or other feeding
device so that incoming material hits the center of
the shaft nut.
• If using a feed box, position the box so that incoming
material hits the center of the distributor plate. To
help prevent excessive wear, the feed box should
contain a rock shelf.
• Do not place the feed chute or feed box too close to
the crusher. Uneven distribution of material could
result. Refer to the Assembly Drawings (provided
separately with this manual) for proper dimensions
and clearances.
• It is recommended that any excessively fine or sticky
material be removed from the feed before it enters Figure 3–16. Feed Arrangement
the crusher. A buildup of this material can result in a
A – Feed Chute C – Centrally Located
packing condition inside the crusher. Reduced B – Rock Shelf Feed Box
crushing performance and excessive upper frame
movement may occur.
• If rebar or other metal objects will be present in the
feed, an electromagnet placed ahead of the crusher
is mandatory.
• If needed, install a surge bin of adequate capacity.
The surge bin will help ensure that the crusher
receives a steady amount of feed at all times.

DISCHARGE ARRANGEMENT MOTOR & DRIVE INSTALLATION

• Design and install the discharge hopper in
accordance with the Assembly Drawings provided Electric Motor Installation
separately with this manual. Also see Figure 3-14. • Refer to Table 3-1 for motor horsepower
requirements. Also see the Assembly Drawings
provided separately with this manual for additional
motor data.
• Read and understand the motor manufacturer’s
m a n u a l s. Fo l l ow a l l a p p l i c a bl e i n s t a l l a t i o n
instructions and safety precautions when installing
the motor.
• If an autotransformer starter was included with the
shipment, refer to the electrical schematics which
A have been supplied separately with this manual.
• Verify that voltage, phase and frequency are correct.
See the motor nameplate for the electrical power
requirements of your motor.
• Totally enclosed, fan cooled, normal torque motors
are recommended for most applications. Contact
your Telsmith Dealer or the Telsmith Ser vice
Department if you have questions about the motor
requirements for your crusher.
Figure 3–17. Discharge Hopper Installation V-Belt Drive Installation

A – Discharge Hopper • See the installation drawings provided with this
manual for V-belt drive installation diagrams. Refer
• Provide inspection doors or panels so that the to Chapter 11 for V-belt tension adjustment
discharge area is easily accessible for routine procedures.
maintenance.
• Unless absolutely necessary, do not mount the
• Do not place the discharge hopper too close to the motor more than 30 degrees from the horizontal
crusher. A backup of material may occur if adequate centerline of the flywheel sheave.
“free fall” clearance is not provided under the
crusher. Serious internal damage to the crusher • Install the motor on adjustable slide rails only. DO
could result. NOT install the motor on a pivoting motor base.
• Be certain that the slide rails have a sufficient range
INSTALLING THE OIL LUBRICATION of adjustment to accommodate future V-belt stretch,
SYSTEM AND HYDRAULIC POWER and to allow installation of new V-belts without
UNIT forcing.
• Install the oil lubrication system and prepare it for • After installing V-belts, check that the sheaves
operation. Refer to Chapter 4 for installation remain precisely aligned and that tension is correct.
instructions, oil specifications and hose connections.
• Install the hydraulic power unit and prepare it for
operation. Refer to Chapter 8 for installation
instructions, oil specifications and hose connections.

Countershaft Speed & Direction of Rotation

• After making electrical connections, jog the motor
and ver ify that the flywheel sheave rotates
CLOCKWISE. Reverse electrical leads if necessary.
See Figure 3–15.
IMPORTANT:
CLOCKWISE ROTATION
Rotation of the flywheel sheave in the opposite ONLY
(counterclockwise) direction may cause gradual
loosening of the crusher shaft nut. Serious internal
damage to the crusher could result. Such damage is not
covered under warranty.
• Use a tachometer to measure countershaft speed at
the flywheel sheave. Countershaft speed must be
checked immediately after the crusher is started for
the first time.
• Actual countershaft speed must be within 3 percent
of the recommended countershaft speed shown in
Table 3–1. Higher speeds may damage the crusher.
Lower speeds will result in reduced production.
Figure 3–18. Countershaft Direction of Rotation
Table 3–1. Horsepower and Speed Specifications
Required Countershaft Speed

Model
Electric Motor Horsepower Measured at Flywheel Sheave
38BS 150 - 200 Desired Speed : 780 RPM

Speed Range: 757 - 803 RPM
44BS 200 - 300 Desired Speed: 677 RPM
Desired Speed: 600 RPM
52BS 300 - 400
Speed Range: 688-731 RPM
Speed Range 548 - 582 RPM
NOTE:
• Refer to the assembly drawings provided with your crusher for sheave sizes, drive dimensions and V-belt specifications.
• Horsepower requirements shown above are for electric motors only. Diesel horsepower is rated differently. If your crusher will be
powered by a diesel engine, contact the Telsmith Engineering Department for diesel horsepower requirements.
• Countershaft speeds shown above are for an empty crusher. The RPM will drop slightly after the material feed is started. However,
the difference between full load and no load RPM will be less than 3% for most crushers.
• Specifications and data shown above are for general reference only, and may not be applicable to all crushers, due to custom
engineering, product improvements or other design variables.
CAUTION: Changes to Drive Speeds must be reviewed by Telsmith or warranty will be voided.

V-Belt Drive Guard Installation • Prepare the engine for operation in accordance with
t h e e n g i n e m a n u fa c t u r e r ’s i n i t i a l s t a r t - u p
• If a V-belt drive guard is not supplied with the
instructions. Completely follow all recommended
crusher, it is the user’s responsibility to fabricate and
break-in procedures. Observe all safety precautions
install a guard that fully complies with all federal,
as outlined in the operator’s manuals.
state and local regulations. The guard should be
well-ventilated to prevent excessive heat build-up.
• On user-supplied V-belt drive guards, provide a
IMPORTANT:
small access hole opposite of the crusher All diesel engines must be equipped with an electric
countershaft. This opening will allow countershaft shut-off device that immediately stops the engine when
speed to be checked without removing the guard. the cr usher alar m is activated. It is the user’s
Install a door or plate to cover the access hole when responsibility to install and properly connect the shut-off
not in use. device. Refer to Chapter 4 for alarm wiring diagrams.
• Check that the V-belt drive guard is properly
installed. Be sure that the guard does not make INITIAL START-UP
contact with any V-belt drive components. 1. Read and fully understand the crusher operating
instructions contained in this Manual. Be familiar with all
! WARNING crusher features and functions.
Correct installation and placement of guards is 2. Locate the Initial Start-up Checklist. and the Alarm
the user’s responsibility. All guards must be and Interlock Checklist. These checklists are shipped
installed and maintained in accordance with all loose with all new crushers. Keep both checklists handy
federal, state and local regulations. Failure to during the initial start-up period.
observe this precaution may result in an
entanglement hazard. Serious personal injury or NOTE:
death could occur.
See back of this chapter for a duplicate copy of the Initial
Start-up Checklist. Refer to Chapter 4 for a duplicate
DIESEL ENGINE PREPARATION copy of the Alarm and Interlock Checklist.
(If Equipped)
3. If not done previously, adjust the crusher discharge
• Be certain that the diesel engine is properly sized for setting as described in Chapter 8. After making
the crusher. Contact your Telsmith dealer or the adjustments, check that the discharge setting is not set
Telsmith Engineer ing Depar tment for diesel too small. There must be no contact between the mantle
ho rsep owe r req uire me nts. No te th at dies el and the concave ring at any point.
horsepower is rated differently than electric
horsepower.
• Read and understand the operator’s manuals
provided with the engine. If present, also refer to any
a d d i t i o n a l o p e r a t o r ’s m a n u a l s fo r e n g i n e
accessories (power take-off, auxiliary pump drive,
etc.).
• Follow the engine manufacturer’s instructions when
unpacking the diesel engine and preparing it for use.
Check all fluid levels. If it is necessary to add fluids,
use only recommended fluids of the proper
specifications.
• If the engine is equipped with a power take-off
(PTO), read the PTO operator’s manual for start-up
checks and adjustments.

4. Place match marks on the crusher drive ring and on 8. Remove the inspection cap from the oil tank. Check
the locknut. These marks will be used to check for that a sufficient flow of oil (about 1/3 to 1/2 pipe) is
support bowl movement after the crusher is started. See returning to the tank. Also verify that a steady stream of
Figure 3–16. oil is visible through the countershaft box site gauge.
9. Install the hydraulic power unit and prepare it for
o p e ra t i o n . R e fe r t o C h a p t e r 8 fo r i n s t a ll a t i o n
A instructions, oil specifications and hose connections.
PLACE 10.Place the hydraulic system in crush mode and allow
MATCH time for the relief circuit to pressurize. Verify that the
MARKS
hydraulic pressure gauge indicates approximately 3000
HERE.
psi. Refer to Chapter 8 for hydraulic system operating
instructions.
B
11.Complete sections I and II of the Initial Start-up
Checklist. Have a licensed electrician complete
sections A through D of the Alarm and Interlock
Checklist.
12.Check the oil return line temperature. It must be at
least 50°F (10°C) before starting the crusher. In very
cold climates, approximately six to eight hours may be
needed for the heaters to adequately warm the oil.
13.Walk completely around the crusher. Be sure no
personnel are on, inside or near the machine. Sound a
warning horn to alert others that the crusher is about to
be started.
14.Start the crusher drive motor or diesel engine. As a
Figure 3–19. Checking for Support Bowl Movement precaution, check oil system pressure, temperature and
flow immediately after crusher operation begins.
A – Drive Ring B – Locknut
15.Run the crusher empty for a few minutes. Continue
5. Lockout/tagout power to the crusher drive. to closely watch all gauges and indicators. Look and
6. Temporarily block the flywheel so it cannot turn. listen for any obvious signs of trouble, such as
Manually rotate the head counterclockwise a full 360° excessive vibration or abnormal noises.
by hand. Verify that the head turns independently of the
eccentric and is not frozen or sticking. If the head will not
turn:
• Verify that all wooden shipping wedges have been
removed from between the mantle and concave ring.
• Check that the crusher discharge setting is not set
too small. Refer to Chapter 8. There must be no
contact between the mantle and the concave ring at
any point.
IMPORTANT:
If the head does not rotate freely after making the
previous checks and inspections, contact your local
Telsmith dealer or the Telsmith Service Department.
7. Start the oil pump as described in the Daily Start-up
procedures in Chapter 4. With the crusher off, allow the
oil to circulate for at least 15 minutes.

16.Check the oil return pipe filter collector. A few 26.Complete section III of the Initial Start-up Checklist.
metallic particles may appear on the screen of the
collector after the crusher is started for the first time.
However, an excessive amount of metallic particles
should not be present.
IMPORTANT:
Stop the crusher immediately if an excessive amount
of metallic particles or flakes has accumulated on the oil
filter collector screen. Contact your Telsmith dealer or
the Telsmith Service Department before restarting the
crusher.
17.Check countershaft speed (RPM) at the flywheel
sheave. Be certain that the countershaft direction of
rotation is clockwise. Reverse electrical leads if
direction of rotation is not correct. See Figure 3–15.
18.Wait until the return oil temperature rises to at least
70°F (21°C). Then start the material feed. Gradually
increase the feed rate until the chamber becomes
completely filled. Verify that the head reverses direction
and begins turning slowly counterclockwise.
19.Gradually reduce the feed rate until the crusher is
operating at approximately 50 percent capacity. Use the
ammeter as a guide.
20.Verify that the material feed is directed toward the
center of the crusher, and is hitting the shaft nut. Be
sure that material is evenly distributed 360° around the
crushing chamber.
21.Crushers equipped with anti-spin option: Verify
that the head continues tur ning slowly
counterclockwise during crushing. If the head stops
turning, gradually increase the feed rate as required
until counterclockwise rotation is resumed.
22.Crushers NOT equipped with anti-spin option:
Ve r i f y t h a t t h e h e a d c o n t i nu e s t u r n i n g s l ow l y
counterclockwise during crushing. If the head begins
to turn clockwise, gradually increase the feed rate as
required until the head reverses direction and
counterclockwise rotation is resumed.
23.Check match marks on the drive ring and locknut
cover. Verify that NO movement has occurred. See
Figure 3–16. The
24.drive ring and locknut should remain completely
stationary during crushing.
25.Verify that there is NO noticeable up-and-down
movement of the upper frame. Such movement is
usua lly cau sed by a packin g co nditio n a nd/or
uncrushable objects in the feed.

NEW CRUSHER BREAK-IN

IMPORTANT:
Break-in the new crusher as follows:
Be alert for any obvious signs of trouble or improper
Day One: 0-8 hours - Feed the Crusher at or below operation. If any problems are noticed, take immediate
50% through-put capacity at the designated Closed corrective action to prevent possible mechanical
Side Setting per the application. Do Not Exceed 50% of damage to the crusher.
the connected Full Load Power of the Crusher Drive
Motor (kW, HP or FLA if electric). For crushers without During the first day of the break-in period, complete
an anti-spin device, attempt to feed enough material to sections II, III, IV, V and VI of the Initial Start-up
stop the head from rotating clockwise (see instructions Checklist. Also complete section E of the Alarm and
below). Interlock Checklist.
Day Two: 8-16 hours - Increase the feed rate until the Mail the completed checklists to the Telsmith Service
crusher is at or below 75% through-put capacity at the Department using the envelope enclosed with the
designated Closed Side Setting per application. Do Not manuals. The checklists must be received within seven
Exceed 75% of the connected Full Load Power of the days of start-up to validate Telsmith’s new product
Crusher Drive Motor (kW, HP or FLA if electric). warranty.
Day Three: More than 16 Hours - Increase the feed

rate to 100% of the crusher’s through-pu capacity at the
designated Closed Side Setting per application. Do Not •50%
Exceed the connected Full Load power of the Crusher Capacity
Drive Motor (kW, HP or FLA if electric). First Day
Carefully regulate the feeding device so that the proper
amount of feed is supplied to the crusher during each
day of the break-in period. Use an ammeter reading •75%
(Fig. 3-17) or a pressure gauge as a guide. Capacity
Ke e p t h e c h a m b e r s u f f i c i e n t l y f i l l e d s o t h a t Second
counterclockwise rotation of the head is always Day
maintained. However, be careful not to overfeed the
crusher. An excessive amount of feed during the •100%
break-in period will damage the bronze sleeves and Capacity
cause premature failure. They need to be lightly Third Day
loaded during the break-in period.
As required, make the following observations and
inspections during the break-in period:
• Check all gauges and indicators at least every 30 Figure 3–20. New Crusher Break-in
minutes. Investigate any abnormal or rapidly
changing readings.
NOTE:
• Check V-belt tension every 8 hours. Readjust
Operation at full rated amps is approximately equal to
tension as required. Refer to Chapter 11 for tension
100% capacity. See the motor dataplate for the full
adjustment instructions.
rated amps of your motor.
• After every 8 hours, check that the mantle remains
tight and that there are no broken welds between the
burning ring and the mantle. These problems are
very unlikely, but can occur in some situations.

NOTES

Mail to: Important:

Telsmith, Inc. Mail Signed Checklist
Attn: Service Department within 7 days of start-up
to maintain warranty.
P.O. Box 539
Mequon, WI
U.S.A.
INITIAL START-UP CHECKLIST

Telsmith SBS Cone Crushers
CUSTOMER INFORMATION: SECTION 1- Pre Start-Up Checks cont.
Customer Name / Address V-BELT DRIVE

Sheaves properly aligned and installed.
All bolts tight.
Dealer Name / Address V-belt tension adjusted correctly.

Drive guard installed.
OIL SYSTEM
Checklist completed by Oil system mounted on solid foundation or
structure.
Oil return piping slopes downward from crusher
Date drain.
Crusher Model Oil cooler properly installed and connected.

Serial Number Oil tank filled. Oil level about 3/4 inch from top
of sight gauge. (Name and grade of oil used:
Customer Signature : _____________________________________ ) .
Oil pump turns in correct direction.

SECTION 1- Pre Start-Up Checks
Alarm horn stops when pressure and flow reach
FOUNDATION normal levels.
Crusher mounted on solid foundation or
Oil flow visible in countershaft box sight gauge.
structure.
Crusher grouted or shimmed level. Adequate oil flow returning to tank (about 1/3
to 1/2 pipe).
Crusher mounting nuts tight.
No oil leaks.
CHUTES AND HOPPERS
DIESEL ENGINE (if equipped)
Feed chute adequately sized and properly
positioned. Engine properly installed and prepared for
operation.
Discharge hopper adequately sized and properly Engine fluid levels checked.
positioned.
Engine manufacturer’s manuals read and
Chutes and hoppers have proper clearance. understood.
Chutes and hoppers free of obstructions. ELECTRIC DRIVE MOTOR
Motor starter equipped with proper size overload
CRUSHER
heaters.
Discharge setting correct ( ________ inches).
Motor wired for proper voltage (AC volts ________
Crushing chamber clear. HZ _________ ).
Ammeter installed and properly wired.
Head turns independently of eccentric 360 degrees.
(When turned counterclockwise by hand

SECTION 1- Pre Start-Up Checks cont. SECTION 2- Crusher Initial Start-Up
Hydraulic System Oil System

Power unit mounted on solid foundation or structure. Oil pressure checked at startup: _________PSI
Isolation mounts installed at all four corners of Oil Flow checked at startup: _________GPM
power unit.
Oil temperature (return line) checked at
Hydraulic reservoir filled. Oil level up to black line of start-up: ______________oF.
sight gauge. (Name and grade of oil used :
___________________________________ ). Electric Drive Motor
Power rotator gearbox oil level checked. Oil level up Flywheel sheave rotates CLOCKWISE
to top of oil level tube
Hoses properly connected to power unit and crusher. Flywheel sheave speed is _____________RPM with
crushing chamber empty.
Power unit low pressure switch wired to crusher Electric motor draws __________amps with crusher
motor starter. running empty.
Hydraulic pump turns in correct direction.
All hydraulic functions operate properly. Diesel Engine (if equipped)

Engine starts and operates properly.
Pressure gauge indicates correct PSI in CRUSH
mode (+/- 50 PSI) for your model: Power take-off engages properly.
MODEL CORRECT PSI SETTING Flywheel sheave rotates CLOCKWISE.

38 2200 PSI Engine speed is _____________ RPM with crusher
44 2200 PSI running empty.
52 2200 PSI
57 3000 PSI Engine gauges and indicators show normal readings.
68 2200 PSI
Pressure gauge indicates correct PSI in EXTRACT

mode (+/- 50 PSI) for your model:
MODEL CORRECT PSI SETTING

38 1100 PSI
44 1100 PSI
52 1500 PSI
57 1500 PSI
68 1500 PSI
Hydraulic filter indicators show green.
No oil leaks
ALARMS and INTERLOCKS

Electrical connections checked.
All alarm functions operate properly.
All Interlocks operate properly.
Alarm horn sounds when horn test pushbutton is
depressed.
Alarm and Interlock Checklist completed.
Important: The Alarm and Interlock Checklist
(provided seperately) must be completed before
crusher start-up. Failure to complete and mail the
signed checklist may void warranty.

SECTION 3- Material Introduction SECTION 4- Checklist First Day Operation

Feed Arrangement Oil Pressure:
Feed distributed 360 degrees around crushing 1. @ Start-up PSI:
chamber.
2. @ two hours PSI:
Feed rate 50% during first 8 hrs., 75% during the
next 8 hrs., and 100% thereafter. 3. @ four hours PSI:
Head rotates slowly counterclockwise when chamber 4. @ six hours PSI:
is filled.
5. @ eight hours PSI:
Head stops turning when chamber is empty (w/anti-
spin option only). Oil Flow:
No material back-ups in discharge area. 1. @ Start-up GPM:
2. @ two hours GPM:
Oil System
3. @ four hours GPM:
Oil pressure, flow and temperature remain within
acceptable limits. 4. @ six hours GPM:
No metallic particle accumulation on oil return filter. 5. @ eight hours GPM:

Oil Temperature:
Oil filter indicator moves to OK zone after oil warms.
1. @ Start-up oF:
Air-oil cooler fan turns on and off at the proper
temperature (if equipped). 2. @ two hours oF:
Oil heaters turn on and off at the proper temperature. 3. @ four hours oF:
Crusher 4. @ six hours oF:
No up-and-down movement of upper frame during 5. @ eight hours oF:
crushing.
Support bowl does not turn or creep during crushing.
SECTION 5- General Information
Flywheel sheave speed is ______________ RPM
after material feed is started. Electric Motor Data:
Motor current draw is ______________ amps after 1. Manufactured by: __________________ .
material feed is started. 2. RPM ______________ .
RPM remains constant (within 5%) after material 3. Horsepower _______________ .
feed is started. 4. Full load ampere rating _______________ .
Diesel Engine Data: (if equipped w/diesel engine)
1. Manufactured by : ___________________ .
2. Size ___________________ .
3. Horsepower____________________ .
Material Being Crushed At Time Of Test:
1. Common Name of Material ___________________
_________________________________________ .
2. Sieve analysis of feed________________________ .
3. Sieve analysis of product (attach separate sheet)
Crusher set at _________ discharge opening.
4. Compressive strength of material ______________
_________________________________________ .
5. Silica content of material ___________________
________________________________________ .

Chapter 4
Lubrication System, Installation and
Assembly
CONTENTS
LUBRICATION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LUBRICATION SYSTEM ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ELECTRICAL INTERLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
LUBRICATION COMPONENT ID CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
LUBRICATION SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
LUBRICATION SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Locating the Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Installing Feed and Return Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
ALARM INSTALLION AND WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Alarm Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Alarm Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Alarm Wire Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Alarm Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Alarm Panel & Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Oil Flow Switch (Non Trac10 Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Oil Flow Switch (TRAC10 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SENSOR SWITCH SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Oil Pressure Switch (Non-TRAC10 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Changing High/Low Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Output 1 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Viewing High and Low Pressure Values. . . . . . . . . . . . . . . . . . . . 4-16
Changing Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Oil Pressure Switch (TRAC10 Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lubrication Supply Temperature Sensor (Non-Trac10 Models. . . . . . . . . . . . . . . 4-17
Changing Hi/Low Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Lubrication System, Installation and Assembly Operation and Maintenance
Changing Display Units 4-18

Lubrication Return Oil Cooler Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . 4-18
Changing Hi/Low Limits 4-18 Changing Display Units 4-20
Viewing High and Low Values 4-19
ELECTRICAL HOOKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Connecting the Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Connecting the Oil Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
LUBRICAION SYSTEM FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
LUBRICATION SYSTEM INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
ALARM & INTERLOCK CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Operation and Maintenance Lubrication System, Installation and Assembly
LUBRICATION SYSTEM DESCRIPTION ELECTRICAL INTERLOCKS

The lubrication system provides a continuous supply of Three electrical interlocks function in conjunction with the
pressurized oil to lubricate the crusher’s internal parts. In lubrication system. They prevent the crusher from being
addition, it also heats or cools the oil as required to maintain started under the following conditions:
stable oil temperatures during changing crusher loads and
• If the oil pump is OFF.
varying environmental conditions.
• If the alarm panel door is open.
The lubrication system’s electric oil pump operates
independently of the crusher drive. It allows oil to be • If hydraulic relief pressure is below acceptable limits.
circulated before crusher start-up, providing pre-lubrication
Immediate crusher shutdown will result if any of these
for the crusher’s internal components.
conditions occur while crushing.
Major components of a typical lubrication system are shown
in Figures 4-1 and 4-2. The actual location of some
components may vary, depending on crusher mounting style
and other factors. Some components shown may not be
present on your oil system, due to design variables,
engineering changes or other factors.
For most stationary crushers, the lubrication system
components are pre-installed on a fabricated steel base.
However, if the crusher is mounted on a Telsmith portable
plant, these components may be configured in suitable
locations on the plant chassis.
LUBRICATION SYSTEM ALARM

The alarm is an integral part of the lubrication system.
Detailed alarm installation and hookup instructions are
located later in this chapter.
During crusher operation, any of the following abnormal
conditions will sound the alarm horn and result in a time
delayed crusher shutdown:
• Low feed-line oil flow.
• Low feed-line oil pressure.
• High supply line oil temperature.
An abnormal condition must occur for at least five seconds
before the alarm is triggered. This time-delay prevents
momentary fluctuations in pressure, flow or temperature from
activating the alarm and interlocking the crusher drive.

LUBRICATION COMPONENT ID CHART
D
A AA
(Non TRAC 10)
Z
C
B VIEW A
L
Y
(See View E) E X
F VIEW B W
V
G
U
H
(See View C)
Main Frame
K Oil Supply
(See View B)
I
(See View D) J T
M
S
P
R
O
Anti-Spin Unit
VIEW C N Input Oil Supply
Figure 4–21. Oil System Major Components
A.Tank Return Inlet I. Oil Pump Assembly Q. Temperature Sensor Switch Y. Output Line
B. Air/Oil Cooler Switch J. Oil Heaters R. Oil Supply Line Z. Flow Meter Switch
C. Return Pipe Oil Strainer K. Oil Cooler Hoses S. Bottom Plate AA. Oil Filter Assembly
D. Cap L. Oil Cooler T. Anti-Spin Gearbox
E. Oil Filter Assembly M. Thermo Bypass Valve U. Oil Supply Line
F. Oil Tank Return Inlet N. Relief Valve V. Main Frame
G. Oil Tank Cover O. Oil Filter Drain Valve W. Bypass Line (To Oil Cooler)
H. Manifold P. Pressure Sensor X. Return Line (From Oil Cooler)

E T
A U
F
V
Countershaft Bearing
Input Oil
G Supply
C
VIEW D
R
D
H Q
VIEW E
P
I
O
Flow Meter M
(TRAC 10 equipped crushers) K
Figure 4–22. Oil System Major Components (cont.)
A. Oil Filter Cap E. Element Connector I. Flow Sensor M. Oil Pump P. Pump Motor Adapter T. Oil Line
B. Upper Filter Element F. Lower Filter Element J. Sensor Pick-Up N. Oil Supply Pickup Q.Guard U. Sight Gauge
C. Bypass Indicator Valve G. Oil Filter Housing K. Oil Output Port O. Oil Tank Mounting R.Coupling V. Countershaft Box
D. Manifold H. Relief Return Line L. Oil Output Line Plate S.Oil Pump Drive Motor Oil Supply

LUBRICATION SYSTEM FLOW A continuous supply of oil is provided to the major internal
components of the crusher, such as the bronze sleeves, thrust
Oil is drawn from the tank by an electrically powered internal bearing, the main shaft and the eccentric. A series of internal
gear pump. On some systems, a check valve is installed in the oil holes and ducts delivers oil between the crusher’s moving
pump suction line. However, this valve is not required for parts (Fig. 4-3).
most installations.
Some of the oil flows past the thrust bearings and spills onto
After exiting the pump under pressure, the oil passes through the main drive gear and pinion. A small portion of this spilled
a filter that removes dirt and other impurities. If the oil oil is diverted to an internal passage in the countershaft box,
temperature is 95oF or greater the output oil flow begins to be providing lubrication for the inner countershaft bearing.
diverted by the thermo bypass valve (Fig. 4-1) to the oil
cooler. If the oil temperature reaches 110oF, the full flow of Separate external oil lines (Fig. 4-3) supply lubrication to the
oil is diverted to the oil cooler before being circulated in the outer countershaft bearing and to the anti-spin gearbox (if
crusher. equipped).
The oil cooler may be either the water-oil or air-oil type. All oil eventually drains into a sump at the bottom of the
Some oil systems are equipped with both types of coolers if crusher main frame. Piping then directs the oil back to the
additional cooling capacity is required. tank by gravity. The oil is filtered again by a strainer (Fig.4-
1) as it re-enters the tank.
Figure 4–23. Lubrication System Flow
A. Main Frame Oil Input B. Return Oil Flow to Oil Tank C. Anti-Spin Oil Input D. Countershaft Bearing Oil Input

LUBRICATION SYSTEM tem from falling rocks or stones.

INSTALLATION
Locating the Lubrication System
Observe the following guidelines when planning the
lubrication system installation:
• Position the lubrication system near the crusher on a level
concrete slab or steel support structure. Do Not mount it on
unstable ground, or in an area where flooding, excessive
dust or falling debris is likely to occur.
• To ensure adequate return oil flow, be sure the lubrication
system is positioned lower than the crusher drain port. For
effective drainage, the oil return piping must have a
downward slope of at least 5 degrees.
• If possible, mount the lubrication system on a seperate
support structure that is independent of the crusher. This
will help provide added isolation from crusher forces and
vibration.
• Allow adequate room above and beside the lubrication
system for routine inspection, lubrication and maintenance
activities. Be sure the following items will be easily
accessible:
- Oil Filter - Oil cooler - Drain plugs
- Tank cap - Oil pump - Tank breather
- Tank cover - Oil heaters
• Make certain all gauges and indicators will be clearly
visible. These devices must not be blocked by walls,
equipment or other obstructions. Figure 4–24. Lifting the Lubrication System
Installing the Lubrication System

Installing Feed and Return Lines
! WARNING Connect the oil feed and return lines as shown on the Oil
Do Not allow personnel under the lubrication Piping Assembly Drawing (provided seperately with this
system while it is being lifted. Always use suitable manual). Observe the following guidelines and instructions:
rigging and hoisting equipment to stabilize and lift • Oil return piping must slope downward from the crusher
heavy objects. drain port to the tank. To ensure proper oil flow, verify that
1. Refer to the bill of lading or packing list for the actual the piping has a downward slope of at least 5 degrees, or
weight of the oil system. If these documents are not about 1 inch (2.5 cm) of slope for every 12 inches (30 cm)
available, refer to Chapter 2 for estimated oil system of pipe. Refer to Figure 4-6.
weights. • Before assembly, check that threaded pipe ends are free of
2. Using an appropriate lifting device, carefully lift the burrs and chips. Be certain the interior surfaces of all pipes
lubrication system and place it on the foundation. See and fittings are free of dust and dirt. Flush as necessary.
Fig 4-4. Evenly support the lubrication system during • Use pipe sealing compound when assembling threaded
lifting. Do Not allow it to drop on the ground or to hit pipe fittings. Be sure all pipe connections are tight.
other objects.
• Avoid using the oil return piping as a means of support for
3. Secure the lubrication system to the foundation with the oil system or any other equipment.
bolts. As required, install shielding to protect the oil sys-

• As needed, place guards around the oil return piping to

protect it against falling material. Support the piping as
required to protect it from vibration and movement.
• Install and connect the alarm sensor switches as described
in the ALARM INSTALLATION AND WIRING section.
• Unless absolutely necessary, do not install flexible rubber
tubing in the return line. Tubing can sag or break from
deterioration, and cause return oil flow problems.
A
• On most crushers, the oil feed hose is approximately 15
feet (4.6 m) long (Refer to Fig. 4-5). Do Not extend this
hose without written approval from the Telsmith
Engineering Department.
• An excessively long suction hose may cause cavitation (a
vacuum within the pump causing air bubbles) and reduced
oil flow. Serious internal damage to the crusher could
result from aerated oil or insufficient oil flow. B
NOTE: Return piping must

slope downhill at least 5o.
Figure 4–26. Oil Return Piping Example
NOTE: A. Air Breather C. Oil Tank Return Inlet

Supply Hose must be B. Drain Port
15 ft. or less in length
Figure 4–25. Typical Oil Feed Hose Routing
A. Main Frame Oil Feed Fitting C. Flowmeter Outlet

B. Countershaft Box Supply Hose

ALARM INSTALLATION AND WIRING However, if an alarm switch fault remains activated for more
than 5 seconds, time-delay relay (TR1) activates the alarm.
This sounds the alarm horn and stops the feeding device.
! WARNING Activation of the alarm also opens control relay (CR1),
Lockout/tagout power before making any electrical immediately stopping the crusher drive motor.
connections to the alarm. Failure to observe this
The alarm has no reset button. When system parameters
precaution may result in serious personal injury or
(temperature, pressure and flow) return to within acceptable
death.
limits, the alarm is de-activated and the crusher can be re-
started.
! WARNING The alarm is designed to quickly stop the crusher before
Failure to properly install and connect electrical serious mechanical damage occurs. However, it also prevents
equipment may result in a dangerous electrical crusher start-up if the oil pressure or flow are below
shock hazard. All connections must be made in acceptable limits, or if the oil temperature is too high.
accordance with the National Electric Code and any
Note that the alarm does not prevent the crusher from being
local regulations which apply. All electrical work
started with cold oil. It is the user’s responsibility to ensure
must be done by a trained and licensed electrician.
proper minimum 50oF (10oC)oil temperatures before starting
Alarm Operation the crusher and 70oF (21oC) before beginning to feed material
to the crusher.
The alarm consists of various electrical components mounted
in the alarm panel cabinet or on the oil tank. Refer to Figures Alarm Installation Guidelines
4-7 and 4-8.
• The alarm is an integral part of the oil system. To ensure
During crusher operation, the alarm continuously monitors protection against oil-related failures, all alarm
the oil system for abnormal conditions, such as low oil flow, components must be fully operational before the crusher is
low oil pressure or high oil temperature. Alarm settings are started.
shown in Table 4-1. An additional return line oil temperature
• Refer to the diagrams in Figures 4-7, 4-8 and 4-9 when
switch (Fig. 4-8) activates the oil cooling fan, but does not
making electrical connections to the alarm components.
activate the alarm.
Refer to other figures as indicated in the installation
Alarm sensor switches are mounted in the oil feed manifold procedures later in this chapter.
and the flow meter switch at the oil tank (Fig. 4-5). The
• If the crusher is mounted on a Telsmith portable plant, the
switches do not activate if oil system operating parameters
alarm components may have been pre-installed prior to
stay within acceptable limits.
shipment. However, most plants will require some
A 5 second time-delay prevents the alarm from being additional wiring and final assembly. Follow all applicable
activated by brief fluctuations in oil temperature, pressure or installation procedures.
flow. If an alarm switch cycles above or below the setpoint
within 5 seconds, alarm activation will not occur.
Table 4-1. Alarm Switch Settings (Alarm Horn Sounds - Crusher Stops)
SWITCH SETTING Model 38/44 Model 52 Model 57 Model 68
Oil pressure switch 20 PSI Open Below Open Below Open Below Open Below
20 PSI 20 PSI 20 PSI 20 PSI
Closed Above Closed Above Closed Above Closed Above
Oil feed temperature 125oF Switch Opens at Switch Opens at Switch Opens at Switch Opens at
sensor switch 125oF 125oF 125oF 125oF
Lube Flow Switch Per Switch Opens Switch Opens Switch Opens Switch Opens
Model below 12 GPM below 20 GPM below 25 GPM below 35 GPM
Note: The alarm is activated if one or more of the switch contacts opens for more than five seconds. All switches should remain closed during normal operation.

Set to 85%
40 60
Note: These two settings will create
a 5 second delay.
80
20
5 100%
100% Set to “6s”
20 F
6S
WARNING: DISCONNECT AND BRANCH

120 VAC, CONTROL POWER CIRCUIT PROTECTION
FROM EXTERNAL SOURCE PROVIDED BY OTHERS
=;
SOLA ,;* ,;+ ,;,
SDN 2.5A-24-100P
2.5 A =;
,+
N L
OIL PRESSURE
SWITCH
9.

,;
E

C D
18;7=.<=
B
!
Figure 4–27. Alarm Components
A. Horn Test Button C. Terminal Block E. Alarm Panel (Door Closed) G. Time Delay Relay (TR1)
B. Alarm Horn D. Control Relay (CR1) F. Alarm Panel (Door Open)

1 (Blu) 2 (Blu) CAUTION: ALL CONNECTIONS, WIRING CHANGES, OR TROUBLESHOOTING

WITHIN THE ELECTRICAL PANEL MUST BE PERFORMED BY
A LICENSED ELECTRICIAN.
Horn + + - -
3 (Blu) 4 (Blu) 5 (Blu)
Test
Power
Supply
11 (Blu)
SOLA Time CRA CRB CRC

Delay
SDN 2.5A-24-100P Relay
Control Relay Control Relay Control Relay
2.5 A =;
Main
Circuit 2 (Blu)
Breaker
N L
10 (Blu)
1C (Blu)
11 (Blu)
2 (Blu)
,+ 2 (Blu)
2 (Blu)
CR1
Horn
11 (Blu)
1C
11 (Blu) Control Relay
(Yel/Grn)
1B (Red) 2 (Blu)
2 (Blu)
2A 8 (Blu)
(Wht) LEGEND:
Incoming PE
Wire No. Wire Color
Line
11 (Blu)
1A 1B 2A 1 1 2 2 3 4 5 8 9 11 20 21 22 23 24 25 G Wire Ratings:
Red - 120V
TYPICAL Brown - 24V
CONNECTOR Blue - 24V
DESIGNATION Black - 24V
SHOWN White - Neutral
Yel/Grn - Grd
Lt. Blue - 24V
1A (Red) Red
Door Black
Switch Flow
1B (Red) Switch
Lt Blue
Lt N.O.
Brown Brown 1 3 Brown 1 3 Blue
Temp Lube
Pressure Flow
1 3 Lt.Blue Switch Switch
2 4 Black 2 4
Temp N.O. N.O.
Switch
2 4 Black Lube Lube
N.C.
Low Pressure Return
Lube
Supply
Temperature Switch Flow Switch (Non-Trac10 Models)

Temperature Switch Pressure Switch
Figure 4–28. Typical Alarm Sensor Interconnection Diagram

SYSTEM OIL PUMP START

3
CR1-1 MS
VOLTAGE MOTOR STARTER STOP PS-1
LINE 20 21
ONLY IF TRANSFORMER TRANSFORMER FROM
IS PROVIDED 1 500VA HYD. PANEL
Typical Crusher Starter Circuitry
1 WARNING: Field Wiring 22 23

120 VAC, CONTROL POWER
FROM EXTERNAL SOURCE Provided By Typical Crusher Starter Circuitry For Device Feeding Crusher
Others
Disconnect And LOAD CRB-1
NEUTRAL 4 24 25
Branch Circuit
Protection Provided LINE
2A Typical Starter Circuitry
By Others Door For Air/Oil Cooler
Switch CB DC Power L2
2 L1 Supply
Only If Transformer 3A 1.3A @ 120VAC #14 AWG
1A 1B 4
Is Not Provided 2.5A @ 24VDC GND ENCLOSURE
+ - DOOR BONDING
CONDUCTOR
1 2 PE
Lube Supply High Temp
Brown Blue
1 3 CRA
Black Lube Supply Temp
3 Relay
2 4
#22/4 Cable
Lube Return Temp
Brown Blue
1 3 CRB
Black Lube Return Temp
4 Relay
2 4
#22/4 Cable
Lube Low Pressure
Brown Blue
1 3 CRC
Black
Lube Press Relay
5
2 4
#22/4 Cable
Flow Switch
Crusher Set At
38 & 44 12 GPM
52 20 GPM
57 25 GPM
CRA-1 CRC-1 Lube Low Flow 68 35 GPM TR1
Off Delay
7 8 9 Set at 5 Sec
#18/ 3 Shielded Cable
Indicates Terminals CR1

Located In 15 TR-1 18 Crusher Relay
Alarm Panel 16 10
Horn Test Horn
11
NOTES: 1. When transformer is provided, wire from two phases of oil pump wiring to transformer (380V, 480V, 575V)
2. When transformer is not provided parallel with oil pump starter coil (120V Only) when crusher oil pump is ON alarm is ON. When crusher oil pump is OFF, alarm is OFF.
3. Oil pump must be interlocked to the crusher starter.
4. Label Neutral wire with “N” at both ends.
Figure 4–29. Alarm Wiring Schematic

• Never attempt to bypass or modify the alarm components Control Relay

during installation. Be sure all alarm switches and other The control relay (CR1) immediately disconnects power to
components are wired and installed as described in the the crusher motor starter when the alarm is activated. It also
following sections. prevents the crusher from being operated if the alarm has no
• Check the alarm switch settings during installation. power.
Although the alarm switches are normally pre-set prior to The CR-1 control relay normally comes pre-mounted and
shipment, all switch settings should be verified as a wired in the alarm cabinet (Fig. 4-11). Typical electrical
precaution. connections are shown in Figures 4-8 and 4-9.
• Test alarm circuit frequently by simulating faults to verify
alarm and interlocks.
Alarm Panel & Time-Delay Relay

Install the alarm panel in a convenient location, where it will
not be affected by moisture or dust. To prevent damage from
shock and vibration, DO NOT mount the alarm panel directly
,;
on the crusher.
If necessary, install a shield above the alarm panel to protect
it from falling rocks. Provide clearance in front of the alarm
panel so that the horn test pushbutton is easily reached.

Make electrical connections to the alarm panel as shown in
Figures 4-8 and 4-9. After wiring, check that the time-delay
relay (TR1) inside the alarm panel enclosure is set at 5
seconds. The 5 second figure is established by setting the
A C
selector at 85% of 6 seconds for a 5 second delay (Fig. 4-10). B
Figure 4–31. Control Relay (CR1) Location
A. DIN Rail Connector C. CR-1 Crusher Control Relay

B. Incoming Control Wiring From
E Sensors
40 60
80
20
5 100%
100%
Oil Flow Switch (Non-Trac10 Models)
20
27. Lockout/tagout power. Read and understand warnings at
6S
D the beginning of the Alarm Installation and Wiring section.
28. Remove front cover of flow meter. The oil flow switch is
located inside the flow meter. See Figure 4-12.
=; 29. Connect wire number 5 to the C (common) terminal of the
switch.
30. Connect wire number 6 to the NO (normally open)
terminal of the switch.
31. Using a screwdriver, slowly turn the screw at the base of
A C the pointer to set the GPM activation point for your model.
B
Verify that the switch is activated at the correct GPM for your
Figure 4–30. Time Delay Relay (TR1) model SBS crusher as shown in the following table:
A. To DIN Rail Connector # 11 C. To DIN Rail Connector #1

B. To Control Relay CR-1 D. Set to “6”
E. Set dial to “85%”

SENSOR SWITCH SETTINGS
SBS Model Activation Setting* Oil Pressure Switch (Non-TRAC10 Models)

The Oil Pressure Sensor Switch used on Non-TRAC10
38/44 12 GPM equipped model SBS crushers monitors oil feedline pressure
52 20 GPM and is installed in the oil tank manifold (Fig. 4-1) and
prewired at the factory. The sensor is preset at the factory for
57 25 GPM both high pressure trigger point and the low pressure reset
point. If it becomes necessary to change the high pressure
68 35 GPM switch ON point, or the low pressure switch OFF point, or
program a replacement switch, the following sequences must
*The correct value must be present to validate warranty be followed.
32. If necessary, readjust the switch setting as follows: Determine the part number on your switch. The following
programming sequences are for part numbers PN 2223 and
A. Using a screwdriver, turn the screw at the base of the
PN 2220 Series 22 switches only!
pointer (Fig. 4.12) until correct GPM is indicated.
IMPORTANT:
B. While holding the pointer in place, depress and turn the
cam ring until the switch is activated (clicks). Release the If your Oil Pressure Sensor Switch displays Loc on the
cam ring. display when you attempt to change parameter values, the
unit has been electronically locked. Remove the clear plastic
C. Slowly move the pointer back and forth several times by protective cover from the switch display. To unlock the unit,
turning the screw at the base of the pointer. Verify that the simultaneously press and hold both the Mode/Enter and
switch is activated at the correct GPM for your model SET buttons until uLoc appears on the display. Parameter
SBS Crusher. changes can now be completed. Re-install the protective
D. Reinstall front cover of flow meter. cover when all changes are complete.
uL o c
Mode/Enter Set
F USED)
(NOT
EWIRE #6
Changing Hi/Low Limits
NO (NORMALLY OPEN)
1. Remove the clear plastic protective cover from the switch
D #5
WIRE
C (COMMON) display. To set the high pressure limit on the switch press the
A
POINTER Mode/Enter button on the top of the sensor several times
until SP1 is displayed.
C
CAM RING
SCREWB
SP 1
Mode/Enter Set
Figure 4–32. Oil Flow Switch
A. Pointer D. Wire #5 (Common) 2. Press the SET button and continue to hold. The current
B. Screw E. Wire “6” “Normally Open”
C. Cam Ring F. Not Used
value of SP1 will flash for 5 seconds. In this case the display
is indicating that the upper value is currently set at the
incorrect value of 21 psi.
Oil Flow Switch (TRAC10 Models)
The Oil Flow Switch (Fig. 4-2) used on TRAC10 equipped
crushers is non-adjustable. The GPM reading from the switch
Mode/Enter Set
2 1
is sent to the TRAC10 which monitors the oil flow.
INCORRECT VALUE

Output 1 Configuration
3. The high value of the SP1 parameter that triggers the
alarm should be 22 psi (1.5 bAr). To increment the value to If a new or replacement pressure switch is installed, it must
22, continue to hold the SET button depressed until the 22 have the Output 1 Hysteris Mode set to: Normally Open
value appears on the display. When the correct value is
reached, release the SET button, then press the Mode/Enter
display. Press the Mode/Enter button on the top of the sensor
button again briefly to set the new parameter value.
several times until OU1 is displayed.
2 2 O U1
Mode/Enter Set Mode/Enter Set
CORRECT VALUE
4. To set the low pressure limit on the switch press the

Mode/Enter button on the top of the sensor several times 2. Press the SET button and continue to hold. The current
until rP1 is displayed. parameter value of OU1 will flash for 5 seconds. If the
Normally Open parameter value (Hno) is present, no change
is necessary. In this case the Hnc (normally closed) parameter
value is the current setting.
rP 1
Mode/Enter Set
Hn c
Mode/Enter Set
5. Press the SET button and continue to hold. The current
value of rP1 will flash for 5 seconds. In this case the display
is indicating that the lower value is currently set at the
incorrect value of 40 psi.
3. To change the setting hold the SET button until the Hno
parameter option appears. Release the Set button then press
4 0 the Mode/Enter button again briefly to set the new parameter
value. Re-install the protective cover on the switch.
Mode/Enter Set
INCORRECT SETPOINT
6. The low limit value that shuts off the alarm and allows the Hn o
crusher to restart operation should be set at 20 psi (1.4 bAr). Mode/Enter Set
To increment the value to 20, continue to hold the SET button

depressed until the 20 value appears. When the correct value
is reached, release the SET button, then press the Mode/
Enter button again briefly to set the new parameter value.
2 0
Mode/Enter Set
CORRECT SETPOINT*
* This value must be present to validate any Telsmith

Warranty.

Viewing High and Low Pressure Values Changing Display Units

Both the highest and lowest measured pressure readings that The factory setting for displayed pressure readings is in
have occurred on the crusher oil system can be called up for Pounds per Square Inch (PSI). If you wish to change your
evaluation. sensor to display metric bAr readings the following steps
must be performed:
display. Press the Mode/Enter button on top of the sensor 1. Remove the clear plastic protective cover from the switch
several times until HI is displayed. display. Press the Mode/Enter button on the top of the sensor
several times until Uni is displayed.
HI
Mode/Enter Set
Uni
Mode/Enter Set
2. To view the highest measured pressure hold the SET

button until the HI pressure psi reading “ __” appears. 2. Press the SET button and continue to hold. The current
Release the Set button then press the Mode/Enter button value (PSI) will flash for 5 seconds.
again briefly to hold the parameter value reading.
3. To view the lowest measured pressure press the Mode/
Enter button several times until LO is displayed. PS I
Mode/Enter Set
LO
Mode/Enter Set
3. Continue to press the SET button until the bAr selection

appears. Release the SET button and briefly press the Mode/
Enter button to set the new parameter value. Re-install the
4. To view the lowest measured pressure hold the SET protective cover on the switch.
button until the LO pressure reading “ __” appears. Release
the Set button then press the Mode/Enter button again briefly
to hold the parameter value reading. Re-install the protective bA r
cover on the switch. Mode/Enter Set
16
Mode/Enter Set
Oil Pressure Switch (TRAC10 Models)

The oil pressure switch supplied on SBS models crushers
equipped with the TRAC10 Remote Automation Control
System is pre-programmed at the factory. No set-up or
adjustment is required of this switch. If a replacement switch
is ordered from Telsmith, it is pre-programmed with the
correct parameter values. No attempt should be made to
change any settings on a TRAC10 unit oil pressure switch.
Changing switch settings could compromise the Diagnostic
and Troubleshooting features of the TRAC10 monitoring
system. Any questions on switch settings with a TRAC10
equipped SBS unit should be directed to Telsmith.

Lubrication Supply Temperature Sensor/ 3. The switch-on value of the SP1 parameter that activates
Switch (Non-TRAC10 Models) the alarm should be 125oF (52oC). To increment the value to
125, continue to hold the SET button depressed until the 125
The temperature sensor switch that activates the alarm and value appears on the display. When the correct value is
shuts down the crusher in oil over temperature situations is reached release the SET button, then press the Mode/Enter
located in the oil tank manifold (Fig 4-1, View C). The oil button again briefly to set the new parameter value.
temperature sensor is a normally closed (NC) switch that
opens at 125oF (52oC) and activates the alarm. When oil
temperature cools to 122oF (50oC), the switch will reclose
and the alarm is shut off. 1 2 5
Mode/Enter Set
Determine the part number on your switch. The following CORRECT VALUE*
programming sequences are for Telsmith part number PN
63A77 switches only! * This value must be present to validate any Telsmith
Warranty.
IMPORTANT:
If your Temperature sensor switch displays Loc on the 4. To set the low temperature limit on the switch press the
display when you attempt to change parameter values, the Mode/Enter button on the top of the sensor several times
unit has been electronically locked. Remove the clear plastic until rP1 is displayed.
protective cover from the switch display. To unlock the unit,
simultaneously press and hold both the Mode/Enter and
SET buttons until uLoc appears on the display. Parameter
changes can now be carried out. Re-install the protective rP 1
Mode/Enter Set
switch cover when all changes have been carried out.
uLoc 5. Press the SET button and continue to hold. The current
Mode/Enter Set
is indicating that the lower value is currently set at 120oF
(49oC).
Changing Lube Supply Temperature Hi/

Low Limits 1 2 0
Mode/Enter Set
display. To change the high temperature limit on the switch
press the Mode/Enter button on the top of the sensor several
times until SP1 is displayed. 6. The low limit value that shuts off the alarm and allows the
crusher to restart operation should be set at 122oF (50oC). To
increment the value to 122, continue to hold the SET button
depressed until the value appears. When the correct value is
SP 1 reached, release the SET button, then press the Mode/Enter
Mode/Enter Set
button again briefly to set the new parameter value.
2. Press the SET button and continue to hold. The current 12 2

value of SP1 will flash for 5 seconds. In this case the display Mode/Enter Set

incorrect value of 110oF.
7. Re-install the protective switch cover when all changes
have been carried out.
1 1 0
Mode/Enter Set
INCORRECT VALUE

Changing Lubrication Supply Display Units Lubrication Return Oil Cooler Temperature
The factory setting for displayed temperature readings is in Switch
degrees Farenheit (oF). If you wish to change your sensor to The oil cooler temperature switch is used in the return line
display readings in degrees Celsius (oC) the following steps (Fig. 4-1, View A) on lubrication systems equipped with an
must be performed: air-oil cooler. It is not electrically wired to the alarm, but
1. Remove the clear plastic protective cover from the switch triggers the oil cooler fan when oil temperature in the cooler
display. Press the Mode/Enter button on the top of the sensor reaches 85oF (29oC).
several times until diS is displayed. Determine the part number on your switch. The following
programming sequences are for part number PN 63A77
switches only!
diS IMPORTANT:
Mode/Enter Set
If your temperature sensor switch displays Loc on the display

when you attempt to change parameter values, the unit has
been electronically locked. Remove the clear plastic
2. Press the SET button and continue to hold. The current protective cover from the switch display. To unlock the unit,
value (oF) will flash for 5 seconds. simultaneously press and hold both the Mode/Enter and
SET buttons until uLoc appears on the display. Parameter
changes can now be carried out. Re-install the protective
o
F switch cover when all changes have been carried out.
Mode/Enter Set
uLoc
Mode/Enter Set
3. Continue to press the SET button until the oC selection
Enter button to set the new parameter value.
Changing Return LineTemperature Hi/Low
o Limits
C
Mode/Enter Set 1. Remove the clear plastic protective cover from the switch
display. To change the high temperature limit on the switch
press the Mode/Enter button on the top of the sensor several
4. Re-install the protective cover on the switch when all times until SP1 is displayed.
changes are complete.
SP 1
Mode/Enter Set

value of SP1 will flash for 5 seconds. In this case the display
incorrect value of 97oF.
9 7
Mode/Enter Set
INCORRECT VALUE

3. The fan switch on point value should be 85oF (29oC). To Viewing Return Line Temperature High and
change the switch on value continue to depress the SET Low Values
button. The value will climb to maximum (257oF (125oC)).
and then switch over to the minimum value (-39oF). Continue Both the highest and lowest measured temperature readings
to depress the button until the correct setting is reached and that have occurred at the oil return line sensor can be called
then release the SET button. Press the Mode/Enter button up for evaluation.
again briefly to set the new parameter value. 1. Remove the clear plastic protective cover from the switch
display. Press the Mode/Enter button on top of the sensor
several times until HI is displayed.
8 5
Mode/Enter Set
CORRECT VALUE HI
Mode/Enter Set
4. To set the low temperature limit on the switch press the

Mode/Enter button on the top of the sensor several times
until rP1 is displayed. 2. To view the highest measured return oil temperature hold
the SET button until the HI temperature reading “ __”
appears. Release the Set button then press the Mode/Enter
button again briefly to hold the parameter value reading.
rP 1
Mode/Enter Set 3. To call up the lowest measured return oil temperature
press the Mode/Enter button several times until LO is
displayed.

is indicating that the lower value is currently set at 72oF
LO
Mode/Enter Set
(23oC).
4. To view the lowest measured temperature hold the SET

7 2 button until the LO temperature reading “ __” appears.
Mode/Enter Set
Release the Set button then press the Mode/Enter button
INCORRECT VALUE again briefly to hold the parameter value reading.
5. Re-install the protective cover on the switch when all
6. The low limit value that shuts off the fan should be set at
75oF (24oC). To increment the value to 75, continue to hold
the SET button depressed until the value appears. When the
correct value is reached, release the SET button, then press
the Mode/Enter button again briefly to set the new parameter
value.
75
Mode/Enter Set
CORRECT VALUE
7. Re-install the protective switch cover when all changes

have been carried out.

Changing Return Line Temperature Display

Units
The factory setting for displayed temperature readings is in
degrees Farenheit (oF). If you wish to change your sensor to
display readings in degrees Celsius (oC) the following steps
must be performed:
display. Press the Mode/Enter button on the top of the sensor
several times until diS is displayed.
diS
Mode/Enter Set

value (oF) will flash for 5 seconds.
o
F
Mode/Enter Set
3. Continue to press the SET button until the oC selection

Enter button to set the new parameter value.
o
C
Mode/Enter Set
4. Re-install the protective cover on the switch when all


ELECTRICAL HOOKUP
IMPORTANT:
! WARNING Interlocks must be operational to validate Telsmith
Warranty.
Always lock out power and tag controls before
making any electrical connections. Failure to CAUTION: ALL CONNECTIONS,
observe this precaution may result in serious WIRING CHANGES, OR TROUBLESHOOTING
WITHIN THE ELECTRICAL PANEL MUST BE
personal injury or death! PERFORMED BY A LICENSED ELECTRICIAN.
! WARNING
Failure to properly install and connect electrical
equipment may result in a dangerous electrical CR1 A
shock hazard. All connections must be made in
accordance with the National Electric Code and any
applicable local codes. Be sure all electrical work is
done by a licensed electrician.
Connecting the Interlocks 1A 1B 2A 20 21 22 23 24 25 G
Connect the oil system electrical interlocks as follows. Refer

B
to the wiring diagrams in Figures 4-8 and 4-9 when making
connections.
5. Lockout/tagout power before making connections.
Read and understand warnings at the beginning of the
Electrical Hookup section.
D
6. Connect the oil pump interlock. The normally open C F G
contact of control relay (CR1) must be wired to the crusher H
starter circuit at terminals 20 & 21 on the DIN rail connector 20 21
(Fig. 4-13). After making connections, verify that the
E
interlock operates as follows:
• If oil pump is OFF, crusher drive motor will not
start. Figure 4–33. Typical Crusher Starter Circuitry
• If oil pump stops, crusher drive motor stops A. Control Relay CR1-1 F. Motor Starter Auxiliary
immediately. B. DIN Rail Connector Contact
C. Stop G. PS-1 Switch
D. Start H. From Hydraulic Panel
E. Crusher Motor Starter Auxiliary
Contact

7. Connect the feeding device interlock. Use terminals 22 8. The alarm panel door switch is prewired to terminals 1A
and 23 of the alarm panel DIN connector (Fig. 4-14). After and 1B of the alarm panel DIN rail (Fig. 4.6). Verify that the
making connections, verify that the interlock operates as door interlock operates as follows:
follows:
- When door switch opens, crusher drive motor, device
- Crusher drive motor and feeding device stop at the feeding crusher and Air/Oil cooler stop due to loss of
same time. DC power supply.
CAUTION: ALL CONNECTIONS, CAUTION: ALL CONNECTIONS,

WIRING CHANGES, OR TROUBLESHOOTING WIRING CHANGES, OR TROUBLESHOOTING
WITHIN THE ELECTRICAL PANEL MUST BE WITHIN THE ELECTRICAL PANEL MUST BE
PERFORMED BY A LICENSED ELECTRICIAN. PERFORMED BY A LICENSED ELECTRICIAN.
A1 15C
+ + - -
A1 25C
A
B A
SOLA
=; SDN 2.5A-24-100P
2.5 A
26 28 A2
,+
15 18 A2
N L
1A 1B 2A 20 21 22 23 24 25 G
B
1A 1B 2A 1 1 2 2 G
E
D Neutral
Line
G 120 VAC, 1 PH
D
Figure 4–34. Typical Starter Circuitry For Device
Feeding Crusher Figure 4–35. Typical Door Switch Circuitry
A. Time Delay Relay (TR1) E. Start Switch
A. DC Power Supply C. DIN Rail Connector
B. DIN Rail Connector F. Auxiliary Contact (Device
B. Circuit Breaker D. Door Switch
C. To Crusher Relay CR-1 Feeding Crusher Motor Starter)
D. Stop Switch G. From Device Feeding Crusher

9. If your unit is equipped with an Air/Oil cooler, the starter Connecting the Oil Heaters
circuit should be wired to inputs 24 and 25 on the DIN rail as
1. Lockout/tagout power before making connections.
shown in Figure 4-16.
Read and understand warnings at the beginning of the
Electrical Hookup section.
CAUTION: ALL CONNECTIONS, 2. Position the oil heaters so that the conduit openings are
WIRING CHANGES, OR TROUBLESHOOTING
WITHIN THE ELECTRICAL PANEL MUST BE facing down or sideways (not up). Connect the oil heaters to
PERFORMED BY A LICENSED ELECTRICIAN. the power source using moisture-proof flexible conduit. Refer
to the electrical schematics in Figures 4-18 and 4-19.
3. Create a drip loop between the oil heaters and the power
source when installing conduit. Check that all electrical
connections are protected from weather, condensation, and
A crusher spill-over. Verify that each heater is properly
CRB
grounded.
4. Check that the heater thermostats are set to the correct
temperature (Fig. 4-17). Refer to Table 4-2 for temperature
settings.
1A1B 2A 20 21 22 23 24 25 G
B
Table 4-2. Temperature Settings - Oil Heaters
OUTSIDE AMBIENT TEMP SET HEATER THERMOSTAT AT:
Below 40°F (4°C) 90°F (32°C)

D C
Above 40°F (4°C) 70°F (21°C)
Figure 4–36. Typical Starter Circuitry for Air/Oil Cooler
A. Control Relay (CRB) D. Input Control Voltage

B. DIN Rail Connector
SET OIL HEATER THERMOSTATS
C. From Cooler Fan Motor Starter
Figure 4–37. Thermostat Setting
A. Set Oil Heater Thermostats B. Rotate Dial

Figure 4–38. Oil Heater Connection (Two-Heater Model)

DISCONNECT
240V LINE
GROUND
THERMOSTATS THERMOSTATS
LOCATED ON LOCATED ON
SAME SIDE SAME SIDE
2 3 OF TANK 2 3 2 3 OF TANK 2 3
1 4 1 4 1 4 1 4
8 5 8 5 8 5 8 5
7 6 7 6 7 6 7 6
1) THE HEATING UNIT REQUIRES ONE SET

OF FOUR ELEMENTS IN PARALLEL.
2) THE CIRCUIT REQUIRES THREE HEATING
UNITS IN PARALLEL FOR 240V.
WIRING DIAGRAM FOR

240V 1PH 60HZ
DISCONNECT
480V LINE
GROUND
THERMOSTATS THERMOSTATS
LOCATED ON LOCATED ON
SAME SIDE SAME SIDE
2 3 OF TANK 2 3 2 3 OF TANK 2 3
1 4 1 4 1 4 1 4
8 5 8 5 8 5 8 5
7 6 7 6 7 6 7 6
1) THE HEATING UNIT REQUIRES ONE SET OF TWO ELEMENTS IN

SERIES, CONNECTED IN PARALLEL WITH ONE SET OF TWO
ELEMENTS IN SERIES.
2) THE CIRCUIT REQUIRES FOUR HEATING UNITS IN PARALLEL FOR 480V
WIRING DIAGRAM FOR

480V 1PH 60HZ
Figure 4–39. Oil Heater Connection (Four-Heater Model)

LUBRICATION SYSTEM - FINAL - In cold climates or where water is scarce, a recirculating

CHECKS water supply and storage tank may be required. Contact
the Telsmith Service Department for additional
Perform lubrication system final assembly procedures as information.
described in the following steps.
5. Portable plants only: If the lubrication system is equipped
1. Inspect the lubrication system for shipping damage. Be with an air-oil cooler, remove the four shipping spacers
sure there are no missing or loose parts. Remove any dirt or (painted red) from the cooler base. Save the shipping spacers
debris. and mounting hardware for future use.
2. Remove any instructional tags or manuals that are 6. If the oil pump was not previously wired, make electrical
attached to the oil system. Save these items for future use. connections to the oil pump at this time. Refer to Figure 4-9
3. Fill the oil tank until the oil level is about 3/4 inch (1.9 cm) for wiring diagram. Also refer to the Electrical Hookup
below the top of the sight gauge (Fig.4-20). Refer to Chapter section for additional instructions. All electrical wiring
5 for oil specifications and capacities. Failure to use the procedures must be performed by a licensed electrician in
correct oil may result in serious damage to the crusher. accordance with the National Electric Code.
Such damage is not covered under warranty. 7. Verify that the oil pump is building pressure by
temporarily starting the oil pump. If the alarm remains on, or
the unit does not immediately build pressure, the pump motor
may be wired incorrectly and the pump impeller is rotating in
the reverse direction. Stop the unit and reverse electrical leads
A
to change direction of rotation. Test the pump again to see if
pressure builds immediately.
A B
Figure 4–40. Oil Level Sight Gauge

C
A. High Mark C. Low Mark
B. Maintain Oil Level at 3/4” (1.9
cm) from top of gauge. Figure 4–41. Water Requirements (Water-Oil Cooler
Only)
4. Lubrication systems equipped with water-oil cooler only:
Connect the water inlet and outlet lines to the cooler. See A. Gallons Per Minute C. Water Temperature at
Figure 4-21 for water flow requirements. Note the following B. Liters Per Minute Cooler Inletk
recommendations:
- A globe valve installed in the water supply line will allow LUBRICATION SYSTEM INITIAL START-
the amount of cooling to be increased or decreased as UP
needed. If automatic regulation is desired, a temperature-
controlled water valve may be used instead. 1. Start the oil pump. With the crusher off, allow the oil to
circulate for at least 15 minutes.
- A flow gauge or sight glass installed at the cooler outlet
will permit water flow to be monitored without
disconnecting the water lines.

2. Remove the oil tank access cap. Check that a sufficient

flow of oil (1/3 to 1/2 pipe) is returning to the tank. Also
verify that a steady stream of oil is visible through the
countershaft box sight gauge.
3. Stop the oil pump and recheck oil level. If the oil level has
dropped, add oil until level is about 3/4 inch from top of the
sight gauge. Up to 30 gallons (113 L) of additional oil may be
required to completely re-fill the system after initial startup.
4. Have a licensed electrician test all alarm and interlock
functions as indicated on the Alarm and Interlock Checklist.
This checklist has been provided separately with this manual.
A duplicate copy of the checklist is provided in Figure 4-22.
IMPORTANT: The alarm and interlock functions must
be completely checked before the crusher is started.
Do not operate the crusher until all alarm and interlock
functions have been thoroughly tested for proper
operation!
5. Wait until the return line oil temperature is at least 50°F
before starting the crusher. Do not begin the material feed
until the return line oil temperature is at least 70°F. Closely
monitor all lubrication system gauges and indicators during
the first several hours of operation.
6. Recheck the return pipe oil strainer (Fig. 4.1, View A)
after starting the crusher. A few metallic particles may appear
in the strainer after the crusher is started for the first time.
However, an excessive amount of metallic particles should
not be present.
7. Verify Lubrication system filter indicator turns to green
when oil is warm (70oF, 21oC).

ALARM AND INTERLOCK CHECKLIST Telsmith Gyrasphere Crushers Operation and Maintenance
ALARM AND INTERLOCK CHECKLIST

Telsmith Gyrasphere Crushers
A. Interlock Operation D. Heating and Cooling Devices
If oil pump is OFF, crusher motor will not start. Note: The heating and cooling devices are not wired to the
alarm. However, they must function properly to ensure
If oil pump stops, crusher motor stops.
reliable alarm operation. Make the following checks:
If alarm panel door is opened, crusher motor stops.
All oil systems:
If hydraulic system low pressure switch opens, crusher
Oil heater thermostats set at 70°F.
motor stops.
(or 90°F if outside temperature is < 40°F)
Feeding device stops if crusher motor stops.
Oil heaters ON when oil temperature falls below
Oil pump remains ON when crusher motor stops. thermostat setting. (Verify that heaters are working)
If equipped with water-oil cooler only:
B. Alarm Operation
Water pump ON.
Alarm horn sounds and crusher motor stops if:
Water flow observed through outlet port of cooler.
Oil flow switch remains open for more than 5 seconds. (Loosen return hose at cooler and check for flow)
Oil pressure switch remains open for more than If equipped with air-oil cooler only:
5 seconds.
Oil cooler temperature switch set at 85°F.
Oil temperature switch remains open for more than (or 105°F if outside temperature is < 40°F)
5 seconds.
Oil cooler fan ON when temperature rises above switch
Additional tests: setting. (Verify that fan is working)
Oil pump remains ON when alarm is activated. Oil cooler fan turns in the correct direction.
Alarm horn sounds when HORN TEST button is (see decal on cooler housing)
depressed.
E. General Information
C. Alarm Settings Customer Name / Address
Time delay relay (TR1) set at 5 seconds.
Oil temperature switch set at 125°F.
Oil pressure switch set at 20 PSI. Dealer Name / Address
Oil flow switch properly set:
MODEL SETTING
38 12 GPM Checklist completed by
44 12 GPM Customer Signature
52 20 GPM
Date
57 25 GPM
68 35 GPM Crusher Size
Serial Number
Figure 4–42. Alarm & Interlock Checklist

Chapter 5
Lubrication System Operation and
Maintenance
CONTENTS
Page
LUBRICATION SYSTEM DAILY STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Before Starting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
After Starting Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
LUBRICATION SYSTEM OPERATING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Oil Pressure & Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
LUBRICATION SYSTEM SCHEDULED MAINTENANCE CHART . . . . . . . . . . . . . . . 5-8
LUBRICATION SYSTEM MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . 5-10

Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lubrication System Maintenance Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Lubrication System - Drain/Clean/Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Oil Filter Indicator Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Oil Filter Elements - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Countershaft Box Sight Gauge-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Oil Tank Breathers - Clean/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Optional Water/Oil Cooler - Inspect Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Air-Oil Cooler-Inspect/Clean/Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Oil Heaters - Inspect, Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
LUBRICATION SYSTEM SEASONAL STORAGE OR LONG TERM STORAGE . . . 5-17

Winter Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Spring (Or Long Term Storage) Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Lubrication System Operation and Maintenance Operation and Maintenance
LUBRICATION SYSTEM DAILY START-

UP
Perform the following steps with the crusher OFF. A
8. Check the oil tank sight gauge. Oil level must be near top
of gauge. Add oil if low. Refer to Table 5-4 for lubricating oil
specifications.
C B C D
Figure 5–44. Clean Air/Oil Cooler
A. Cooler C. Fan Motor Ventilation Fins

Figure 5–43. Oil Tank Sight Gauge B. Air Intake Fan Guard D. Fan Motor Intake Debris
Buildup
A. High Mark C. Low Mark
B. Maintain Oil Level 3/4”
(1.9 cm) from top of
gauge.
9. On crushers equipped with an optional air-oil cooler,

disconnect fan electrical leads to prevent unexpected fan
start-up. Remove the protective screen from the face of the oil
cooler to access the fins. Remove any loose dirt or debris
from the oil cooler fins (Fig. 5-2) (both intake and outflow
sides) . Check the air ventilation intake fins on the back and
the cooling fins on the body of the fan motor. If debris is
present on the fins or in the intakes, remove before startup.
Reconnect fan leads and re-install protective screen when
cleaning operation is complete.

Operation and Maintenance Lubrication System Operation and Maintenance
10. Start the oil pump and listen for the alarm horn (Fig. 5-3)
to sound. Verify that the horn stops after about 20 to 60 A. Return Line D. Return Oil Filter
B. 1/3 to 1/2 Pipe Flow E. Oil Tank Cap
seconds. Required
C. Return Temperature
Sensor
13. Observe the appearance of the oil. Check the oil for
contaminants, foaming or a significant change in oil color
(darker). Change oil and filter elements and determine source
of debris if contaminants are visible or the oil darkens
A immediately. Immediate foaming of the oil may indicate
18;7=.<=
!
water contamination in the system or air pockets in
lubrication components or piping.
14. Check that a steady stream of oil is visible in the
B countershaft box sight gauge (Fig. 5-5).
Figure 5–45. Alarm Horn
A. Alarm Horn B. Alarm Test Button
IMPORTANT: The alarm horn must sound when the oil

pump is started. This indicates that the alarm is
energized. Check the alarm wiring and components if
the alarm horn does not sound. Refer to Chapter 4 for
alarm wiring diagrams.
11. Check lubrication system hoses and piping for leaks.
Repair any leaks before starting crusher.
12. Remove the oil tank cap (Fig. 5-4) and check for a steady
flow of oil returning to the tank. Oil should be visible flowing
out of the complete circumference of the return filter. If oil
flow does not appear to be sufficient shut off the oil pump.
Figure 5–47. Countershaft Oil Sight Gauge
Check oil temperature at return sensor, if oil temperature is
below 70oF (21oC) reach into the tank and unscrew the return 15. Test the oil pump interlock. With the Oil pump OFF,
oil filter. Restart the oil pump and check the flow coming out verify that the crusher motor cannot be started.
of the return pipe. Oil should fill 1/3 to 1/2 of the pipe in a
steady stream if oil flow is correct.
IMPORTANT:
If oil flow appears to be sufficient, reinstall the oil return filter
Crusher motor must not operate unless oil pump is ON.
and the oil tank cap.
Disconnect power immediately if crusher motor starts
turning in step 8. Troubleshoot and rewire the interlock
E
as required. Refer to Chapter 4 for wiring diagrams and
A additional instructions.
Before Starting Crusher

B
Perform the following steps BEFORE starting the crusher.
1. Operate the oil pump for at least 15 minutes with the
D crusher off. Verify that there are no leaks or other obvious
C problems.
Figure 5–46. Oil Tank Return

2. Check the oil pressure sensor reading on the feed line 4. Check the return line oil temperature at the sensor switch
sensor switch (Fig. 5-6) located on the top of the manifold. (Fig. 5-8). The return line oil temperature must be at least
Oil pressure must be at least 20 PSI before the crusher is 50°F (10°C) before the crusher is started.
started.
.
50
20
Mode/Enter Set
Mode/Enter Set
Figure 5–48. Oil Pressure Sensor

3. Check the oil flow meter (Fig. 5-7). The oil flow rate must
B C
be at least the value shown in Table 5-1 for your model
crusher before the crusher is started.
Figure 5–50. Return Line Temperature Sensor Switch
A. Oil Tank Return Inlet C. Return Pipe Oil Strainer

B. Temperature Sensor
Switch
5. Check again for a steady flow of oil returning to the tank

by removing the oil tank cap and observing whether oil is
OIL FLOW flowing out of the complete circumference of the return filter
(1/3 to 1/2 pipe with return filter removed).
Figure 5–49. Oil Flow Meter
Table 5–2. Oil Flow Startup Requirements
SBS Model Required GPM
38/44 12 GPM
52 20 GPM
57 25 GPM
68 35 GPM

6. Check the oil filter indicator (Fig. 5-9 ). The green portion After Starting Crusher
of the indicator must be visible when the oil warms. If the red
portion of the indicator is still visible, a restriction is present 1. Check the return line oil temperature sensor switch (Fig.
in the oil filter. Change the filter elements. 5-8). The return line oil temperature must be at least 70°F
(21°C) before the material feed is started.
2. Recheck the oil return line filter in the tank by unscrewing
the filter. Verify that there is no accumulation of metal
particles (iron, brass, babbit, etc.) in the element.
3. Start the water supply after the oil warms up. Loosen
water hose (Fig. 5-10) to check for return water flow
(crushers equipped with water-oil cooler only).
A
B
A
Figure 5–51. Oil Filter Indicator

C
A. Oil Output C. Filter Assembly B
B. Filter Indicator
7. Push the HORN TEST button (Fig 5-3) to verify that Figure 5–52. Water-Oil Cooler (Optional)
electrical power remains connected to the alarm when the oil
pump is running. A. Water-Oil Cooler C. Check for return water flow
B. Return Line
4. Recheck all oil system gauges and indicators frequently

after start-up. Stop the crusher immediately if any abnormal
or rapidly changing readings are observed.
5. Periodically push the HORN TEST button to verify that
electrical power remains connected to the alarm.

LUBRICATION SYSTEM OPERATING

GUIDELINES
Oil Temperature A 1 25
1. Do not operate the crusher unless the return line oil Mode/Enter Set
temperature is at least 50°F (10°C). Do not begin the material

feed until the return line oil temperature is at least 70°F
(21°C) (Fig 5-11). C
B
7 0
Mode/Enter Set B
A
B
Figure 5–53. Return Line Oil Temp (Material Feed) Figure 5–54. Maximum Oil Temperature Reading
A. Return Line Sensor C. Required Temperature A. MaximumTemperature C. Oil Pressure Sensor Switch
Reading for Material Feed Sensor Setting D. Manifold
B. Oil Feedline
Temperature Sensor
2. Maximum oil temperature is determined by the feed line Switch
oil temperature sensor switch (Fig. 5-12). This switch must
remain set at 125°F (51°C) for all outside ambient 3. Normal oil temperatures will vary, depending on outside
temperatures. Never raise the switch setting to allow crusher ambient temperature, material being crushed and other
operation at higher oil temperatures. Serious damage to factors. However, the return line oil temperature must not
crusher internal components may result. drop below 70°F (21°C) or exceed 125°F (51°C) while
crushing.
4. Be alert for any unusual changes in oil temperature during
crusher operation. If a sudden rise in temperature occurs, stop
the crusher immediately and determine the cause. Make
necessary repairs before resuming operation.
5. After oil temperatures have stabilized, the return line will
usually be about 10 to 12°F warmer than the feed line. The
temperature differential may be less, but normally should not
exceed 15°F. An abnormally large temperature differential
may indicate mechanical problems within the crusher, such as
worn bearings or sleeves.

Oil Pressure & Flow 3. Higher than normal oil pressure accompanied by lower
than normal oil flow may be caused by obstructions in the
1. Oil pressure and flow readings will vary, depending on
crusher feed line or by internal damage to the crusher.
crusher model, oil temperature and other factors. However,
readings must remain within the minimum and maximum 4. If oil pressure and flow are both lower than normal, the oil
limits shown in Table 5-2. pump may need repair or replacement. Low readings can also
indicate obstructions in the pump pickup.
2. When the oil is cold, oil pressure will often be higher than
normal. However pressure should drop to normal levels as the
oil warms up.
Table 5–3. Lubrication System Specification and Settings
Model Item Setting or Specification
All SBS Models Minimum Return Line Oil Temperature 50oF (10oC)
(Before starting crusher)
All SBS Models Minimum Return Line Oil Temperature 70oF (21oC)
(Before starting material feed)
All SBS Models Maximum Return Line Oil Temperature 125oF (52oC)
All SBS Models Typical Feed Line Oil Pressure (@100oF) 30 to 50 PSI (2.1 to 3.4 bar)
All SBS Models Minimum Feed Line Oil Pressure 20 PSI** (1.4 bar)
All SBS Models Maximum Feed Line Oil Pressure 200 PSI (13.8 bar)
38/44 SBS Typical Feed Line Oil Flow 17 to 19 GPM (64 to 72 L/min)
52 SBS Typical Feed Line Oil Flow 26 to 28 GPM (98 to 105 L/min)
38/44 SBS Minimum Feed Line Oil Flow 12 GPM (46 L/min)
52 SBS Minimum Feed Line Oil Flow 20 GPM (76 L/min)
68 SBS Minimum Return Line Oil Flow 21 GPM (80 L/min)
All SBS Models Oil Heater Turn on Temperature 70oF (21oC)1
All SBS Models Air/Oil Cooler Fan Turn on Temperature 85oF (29oC)2
1
90oF (32oC) for cold climates or season
2
105oF (41oC) for cold climates or season

Cold Weather Operation 7. Systems with water-oil cooler only: Disconnect the water
supply to prevent cooler freeze-up during cold weather. If
1. Do not start the crusher until the return line oil
some cooling is still required, a suitable anti-freeze mixture
temperature is at least 50°F (10°C). Do not begin the material
may be circulated through the cooler. Contact the Telsmith
feed until the return line oil temperature is at least 70°F
Service Department for additional information.
(21°C). Failure to observe these guidelines may result in
serious internal damage to the crusher.
LUBRICATION SYSTEM SCHEDULED
2. The oil filter indicator may stay in the RED zone until the
oil warms up. As a general rule, replace filter elements only
MAINTENANCE CHART
if the indicator remains in the red zone at oil temperatures of Perform oil system inspection, maintenance and lubrication
100°F (38°C) or above. procedures as indicated in the Oil System Scheduled
Maintenance Chart, Table 5-3.
3. If needed, the oil pump can remain switched on during
crusher shutdown periods. Circulating heated oil will keep For detailed instructions, refer to the oil system maintenance
the crusher’s internal parts warm until the crusher is started at procedures in the following section. If necessary, also refer to
the next shift. the oil system troubleshooting instructions in Chapter 6.
4. To maintain proper oil temperatures, be sure that power
remains connected to the oil heaters at all times. ! WARNING
5. In areas where outside ambient temperature is Lockout/Tagout power before performing any
consistently below 40°F (4°C), set the oil heater thermostat(s) adjustment, inspection, lubrication,
turn on point to 90°F (32°C) to ensure sufficient heating of maintenance or repair procedures. Disconnect
the oil. Additional oil heaters may be installed for very cold batteries, shut off fuel supply and lockout/tagout
climates. engine controls if crusher is powered by a diesel
engine.
6. Systems with air-oil cooler only: Raise the oil cooler fan
temperature switch turn-on setting to 105°F (41°C), or at least
15 degrees above the oil heater thermostat setting (Fig. 5-13).
For information on changing the return line sensor switch
settings refer to Chapter 4. This temperature differential will
help prevent simultaneous operation of the oil heater
elements and the cooler fan.
1 0 5
Mode/Enter Set B
A
B
Figure 5–55. Cold Weather Fan Switch Setting
A. Return Oil Line Sensor B. Recommended Temperature

Setting for Cold Weather Operation
(< 40oF, 4oC)

Table 5–4. Lubrication System Scheduled Maintenance Chart
INTERVAL CHECK, SERVICE OR LUBRICATE AS REQUIRED
Daily - Before Starting Crusher With oil pump OFF:

• Visually check the entire oil system for obvious damage or loose parts.
• Remove any loose dust and dirt.
• Wipe off all gauges and indicators.
• Check oil tank sight gauge. Oil level must be about 3/4 inch (1.9 cm) from top of gauge.
• Clean dirt from air-oil cooler fins (if equipped with air-oil cooler only).
• Test the oil pump interlock. Crusher must not start when oil pump is OFF.
With oil pump ON:
• Listen for alarm horn when pump is started. Horn should stop after 20 to 60 seconds when pressure and
flow conditions are reached.
• Check hoses and piping for leaks.
• Observe oil system operation. Listen for any unusual noises, rattles or other sounds.
• Check return oil flow to tank (steady flow of oil - 1/3 to 1/2 pipe).
• Check countershaft box oil flow (steady stream of oil in sight gauge).
• Push horn test button. Alarm horn must sound.
• Check RETURN LINE temperature sensor. Be sure display indicates 50°F (10°C) or above
before starting crusher.
• Check all other gauges for proper readings .
Daily - Before Starting With crusher and oil pump ON:

Material Feed • Check RETURN LINE temperature sensor. Be sure display indicates 70°F (21°C) or above before
starting material feed.
• Check all other gauges for proper readings .
• Check the oil filter indicator. Indicator should be indicating Green.
Every 4 Hours • Check all gauges. Stop crusher immediately if any abnormal or rapidly changing readings are observed.
• Check for any unusual noses, rattles, or other obvious indications of trouble.
• Check the oil filter indicator. Indicator must continue indicating Green.
• Push horn test button. Alarm horn must sound.
• Check for oil leaks. Repair any leaks immediately.
Monthly • Inspect the oil tank breather (Fig. 5-20). Clean or replace if clogged.
• Inspect the countershaft breather filter (Fig. 5-14). Replace if clogged.
• Inspect water-oil cooler (if equipped) for leaks. Verify adequate water flow through cooler.
• Inspect air-oil cooler (if equipped) for leaks. Check that fan operates properly. Remove any loose dirt from
cooling fins, fan motor and fan guard.
Every 600 Hours • Completely drain and refill the oil system.
• Clean the oil tank. Remove any dirt or sludge (if present).
• Inspect oil heaters. Remove carbon build-up from oil heater elements (if present).
• Check condition of tank cover gasket. Replace if worn.
• Replace oil filter elements.
As Required • Replace oil filter elements if the filter indicator pops out Red.
• Lubricate air-oil cooler fan motor. Follow motor manufacturer’s lubrication instructions.
(Lubrication not required for motors with sealed bearings)

7. Dispose of used oils in accordance with all federal

regulations, and any state or local regulations that apply. The
proper disposal of oils and other toxic materials is the user’s
responsibility.
8. Non-Flammable cleaning solvents must be used only by
trained personnel and in accordance with manufacturer’s
instructions. Always wear appropriate personal protective
equipment (P.P.E.) when using cleaning solvents.
9. Never disable the alarm or the electrical interlocks.
Oil-Level - Check
1. Stop the crusher. Lockout/tagout power to the crusher
drive. (Refer to Chapter 1 for complete lockout/tagout
procedures).
2. Stop the oil pump. Verify that oil pressure sensor readout
(Fig. 5-6) indicates zero (0) PSI.
Figure 5–56. Countershaft Box Breather (Models 38/
44/68 Only) 3. Allow about 5 minutes for oil inside the crusher to drain
back into the tank. This will provide a more accurate oil level
Lubrication System Maintenance reading.
Procedures 4. Check the sight gauge. The tank is FULL when oil level
is about 3/4 inch (1.9 cm) below the top of the sight gauge.
Lubrication System Maintenance Safety See Figure 5-15.
! WARNING
D
Failure to observe the following precautions may E
result in serious injury or death! F
1. Allow only trained and authorized personnel to perform

oil system maintenance.
2. Use common sense when observing oil system operation.
Be aware of potential hazards at all times. Stay clear of fans
and rotating parts. B
3. Lockout/tagout power to the crusher drive before

beginning any oil system lubrication, maintenance or repair
procedures. Alert all personnel that the oil system is being
serviced.
4. Be sure that the oil pressure sensor switch readout (Fig. 5-
6) on the manifold shows zero (0) PSI before disconnecting
A
oil system hoses or loosening fittings. As a precaution, never
stand directly in front of (or have your face near) an oil or
hydraulic line when “loosening” a fitting. C A
5. Be careful when draining oil. Hot oil can cause burns!

Figure 5–57. Oil Tank Components
6. Avoid unnecessary contact with oils. Wear appropriate
hand protection and protective clothing when servicing the oil A. Oil Heater D. Oil Tank Breather
B. Sight Gauge E. Tank Fill Cap
system. C. Tank Drain F. Oil Level Full

5. If oil level is low, remove the fill cap (Fig. 5-15) and add readout must read zero (0) PSI.
oil as required. Be sure oil specifications are as shown in
3. Remove the oil tank access cover (Fig. 5-16).
Table 5-4. Do not overfill the tank. Oil level must not be
above the oil return filter element. 4. Remove the feed line hose at the crusher. Place the hose
in a suitable container. More than one container may be
IMPORTANT: Always use new oil poured from a clean
required to collect all the waste oil during the following step
container. Never re-use old oil.
as the oil tank can hold 165 gallons if filled to the full mark.
Refer to Table 5-5 for complete lubrication system capacities.
Table 5–5. Lubricating Oil Specifications
Ambient Temperature ! CAUTION

The oil pump must be operated during the following
Specification Below Above step. Be sure that power to the crusher drive re-
40oF 40oF mains locked out.
(4.5oC) (4.5oC)
Viscosity ISO Grade 100 150
Viscosity AGMA 3 EP 4EP

Grade #250.04
D
Viscosity SUS @ 100oF 469-575 709-871
Viscosity SUS @ 210oF 61-67 74-82
Viscosity Index 95+ 95+
Timken OK Load (lbs) 60+ 60+
Extreme Pressure Yes Yes

Agent (EP)
Rust and Oxidation Yes Yes

Agent A C
F E
B
Anti-Foaming Agent Yes Yes
Copper Strip Corrosion Pass Pass Figure 5–58. Oil Tank Components
Test
Oil must not be corrosive to metals generally used in bearings, gears, A. Oil Pump Motor D. Non-Vented Filler Cap
shafts, pumps and housings B. Oil Tank Access Cover E. Oil Tank
C. Oil Tank Cover F. Oil Pump
Oil must have the least possible effect on rubber seals, synthetic seals,
packings and hoses. 5. Start the oil pump and allow oil to drain into the container.
Stop the oil pump immediately when the oil level drops to to
Lubrication System - Drain/Clean/Fill the bottom of the sight gauge. DO NOT allow the pump to run
dry. Several gallons of oil will remain in the bottom of the
tank. Drain the Oil Filter housing (See: Oil Filter Elements -
! WARNING Replace)
Hot oil can cause burns! Stay clear of hot oil during
Remove all drain plugs at the bottom of the tank (Fig. 5-15)
draining procedures. If necessary, allow oil to cool
and at the bottom of air-oil cooler (if equipped). Allow the
to a safe temperature before draining. Wear
remaining oil to drain into suitable containers.
appropriate eye and hand protection during
draining procedures. 6. After draining, thoroughly clean the inside of the tank
with a non-flammable cleaning solvent. Remove any sludge
or deposits as required. Also clean (or replace) the oil return
drive.
filter.
2. Lockout/tagout power to the oil pump to prevent it from
being started during steps 3 and 4. Oil pressure sensor switch

7. Check the condition of the oil heater elements (Fig. 5-15).

Remove any carbon build-up or sludge from the elements.
Verify that the elements are not touching the tank baffles.
8. Clean the mating surfaces of the tank and the tank cover. A
Replace the tank cover gasket if worn or missing. D
B
9. Reinstall all drain plugs.
10. Reconnect the feed line hose to the crusher.
11. Fill the tank with oil. The tank is FULL when oil level is
about 3/4 inch (1.9 cm) below the top of sight gauge (Fig. 5-
1). Do not overfill the tank. Oil level must not be higher
than the oil return line filter inside the tank.
Table 5–6. SBS Lubrication System Capacity
Item Oil Volume Required
Oil Tank 165 gallons (625 L)
Lubrication System 20-35 gallons

Components (76-132 L)
(Oil Cooler, Filter, Oil
Pump, Oil Lines etc.)
C
Actual oil capacity may vary, depending on crusher size,
oil cooler size, oil line length, and other factors.
Capacities for custom engineered oil systems like
portable plants may be different than shown.
Figure 5–59. Oil Filter Indicator
Oil Filter Indicator Check A. Oil Temperature C. Oil Filter Drain Valve
Sensor Readout D. Oil Feed Pressure Sensor
1. Be sure the oil pump is ON. Check that oil temperature is B. Oil Filter Indicator Readout
at least 70°F (21°C) at the return line oil temperature sensor..
2. Observe the filter indicator (Fig. 5-17). The RED Oil Filter Elements - Replace
indicator may be visible when the oil is cold, but should
Refer to Figure 5-18 during the following steps.
gradually indicate GREEN as the oil warms up. This
indicates that the filter elements are in good condition. 1. Stop the crusher. Lockout/tagout power to the crusher
3. Replace the filter elements if the RED indicator remains
procedures).
visible after the oil temperature has reached 100°F (38°C) or
above. See the next paragraph for filter element replacement 2. Lockout/tagout power to the oil pump to prevent it from
procedures being started during the following procedures. Oil pressure
sensor readout must read zero (0) PSI.
3. Clean any loose dirt from around the filter cap. Loosen the
vent plug (J) in the filter cap to relieve any pressure.
4. Pull the oil filter drain valve handle (located on the
manifold beneath the filter Fig. 5-17) out and hold for several
seconds to empty oil in the filter housing and drain it back
into the oil tank.
5. Unthread the cap from the filter housing and remove.

6. Remove the spring and plate. Check for any oil remaining 11. Reinstall the cap. To prevent leaks, tighten the cap to 100
in the filter housing. If oil is still present pull out the drain ft-lbs. (136 Nm).
valve handle again and hold until all oil has drained out of the
12. Start the oil pump and check for any leaks. Also verify
housing.
that the filter indicator shows GREEN.
7. Remove and discard both elements. Save the connector
NOTE: If the indicator remains RED after the oil warms
that was installed in-between the elements!
up, stop the oil pump and verify that the filter elements
are properly installed. Be sure that the connector in-
between the elements is not missing.
Countershaft Box Sight Gauge - Check

J
D procedures).
I 2. Start the oil pump. Check that a steady stream of oil is

visible through the countershaft box sight gauge. See Figure
H 5-19.
C 3. If oil flow is weak or not visible, the sight gauge may be

G damaged or its orifice may be clogged with dirt. The oil feed
line could also be plugged or kinked. Make repairs as
F required.
.
E
B
A
Figure 5–60. Oil Filter Components
A. Oil Filter Indicator F. Plate

B. Oil Filter Housing G. Spring Figure 5–61. Countershaft Box Sight Gauge
C. Lower Oil Filter Element H. O-Ring
D. Connector (Do Not Discard) I. Cap A. Countershaft Sight B. Oil Stream
E. Upper Oil Filter Element J. Vent Plug Gauge
NOTE: Failure to reinstall the connector during the next

step will result in unfiltered oil and inaccurate filter Oil Tank Breathers - Clean/Replace
indicator readings. 1. Stop the crusher. Lockout/tagout power to the crusher
8. Install a new element on each end of the connector. drive. (Refer to Chapter 1 for complete lockout/tagout
Carefully place both new elements into the filter housing as a procedures).
unit. 2. Lockout/tagout power to the oil pump to prevent it from
9. Reinstall the plate and spring. being started during the following procedures. Oil pressure
gauge must read zero (0) PSI.
10. Inspect the O-ring. Replace if worn or damaged.

3. Clean any loose dirt from around the breather. Optional Water-Oil Cooler - Inspect/Clean
If your SBS crusher is equipped with an optional Water/Oil
NOTE: Cooler refer to Fig. 5-21 while performing the following
Model SBS 38/44 and 68 crushers contain a second oil inspection and cleaning:
breather filter (Fig. 5-6) on the countershaft box. Service 1. Stop the crusher. Lockout/tagout power to the crusher
this breather at the same time as the filter located on the drive. (Refer to Chapter 1 for complete lockout/tagout
top of the oil tank. procedures).
4. Carefully unscrew and remove the spin on filter from the 2. Lockout/tagout power to the oil pump to prevent it from
breather pipe on the top of the oil tank (Fig. 5-20) using a being started during the following procedures. Oil pressure
filter strap wrench. gauge must read zero (0) PSI.
5. Check that the holes on the underside of the breather are 3. Be sure the water pump (user-supplied) is OFF.
not blocked by dirt. Replace the breather if clogged or
damaged. 4. Disconnect oil hoses and water lines from the cooler. Plug
the open ends of the oil lines to prevent contaminants from
6. Visually check that the breather pipe is not clogged. entering the oil system.
Remove any dirt or other obstructions from the pipe.
7. Reinstall (or replace) the breather. Be careful not to ! CAUTION
damage the breather during installation.
Use appropriate eye, face and hand protection
when cleaning the cooler. Take care to avoid con-
tact with hot liquids, chemical vapors or other po-
C tential hazards. Be sure all cleaning solutions are
used by trained personnel in accordance with man-
ufacturer’s instructions.
5. Flush the water side of the cooler with high pressure water
to remove any accumulated dirt or sludge. Use a mild alkaline
solution if more thorough cleaning is required. Remove any
other foreign debris if present.
6. If necessary, disassemble the cooler to allow access to the
cooler core. Use a round file or nylon brushes to remove
tightly adhering scale and dirt from the inside of the cooler
tubes. To prevent damage, do not use WIRE brushes.
7. Check the condition of the anodes. Scrape off any built-up
deposits. Replace the anodes if they are badly corroded.
8. Reconnect oil hoses and water lines.
9. Start the oil pump and check for leaks. If leaks are present,
A B tighten fittings and/or and make repairs as required.
10. Start the water pump (user-supplied) and check for leaks.
Figure 5–62. Oil Tank Breather If leaks are present, tighten fittings and/or make repairs as
required.
A. Breather Filter Element C. Oil Filler Cap
B. Oil Filler Breather Pipe

A
A
B
B
C
C
D
Figure 5–63. Water-Oil Cooler
A. Oil Lines C. Anode

Figure 5–64. Air-Oil Cooler
B. Water Lines D. Drain Plug
A. Oil Lines C. Anode
B. Water Lines D. Drain Plug
Air-Oil Cooler - Inspect/Clean/Lubricate
5. Use the following instructions as a general guide when
Refer to Figure 5-22 during the following steps:
cleaning the cooler:
• Remove dirt from cooler fins and tubes.
procedures). • Remove dirt from the fan motor and fan guard. Check that
motor ventilation openings are not obstructed.
being started during the following procedures. Oil pressure • Remove dirt from the fan blades with a stiff brush. To
gauge must read zero (0) PSI. remove solid deposits, use a mild alkaline solution or a
non-flammable solvent. Be careful not to bend fan blades
3. Lockout/tagout power to the air-oil cooler fan or
during cleaning. Bent fan blades may cause excessive
disconnect the fan power leads.
vibration during fan operation.
4. Inspect the cooler for any obvious problems, such as leaks
• If the cooler is greasy, remove the fan motor and apply a
or loose parts. Check that the fan turns freely and is not
non-flammable degreasing solution to the fins and tubes.
blocked by obstructions.
Rinse the solution with hot water or low pressure steam.
Dry thoroughly after rinsing.
• On coolers with vibration isolators, check for worn or
! CAUTION damaged isolators. Inspect isolator mounting hardware.
Use appropriate eye, face and hand protection Replace parts as required.
when cleaning the cooler. Take care to avoid con-
• Sand and repaint any rusty or corroded surfaces.
tact with hot liquids, chemical vapors or other po-
tential hazards. Be sure all cleaning solutions are • To flush the cooler core, disconnect oil hoses and circulate
used by trained personnel in accordance with man- a suitable degreasing agent or flushing agent This will
ufacturer’s instructions. remove any sludge from internal surfaces.

6. If the fan motor is equipped with grease fittings, lubricate 7. After cleaning procedures are completed, refill the tank
the motor in accordance with the motor manufacturer’s with new oil of the proper specifications. Follow the
recommendations. Consult motor manufacturer for procedure earlier in this section.
lubrication intervals and grease specifications.
7. Check the that the return oil line temperature sensor
switch is set to the correct temperature. Refer to Chapter 4 for
recommended settings and additional information.
IMPORTANT: To prevent simultaneous operation of the
cooler fan and the oil heaters, the cooler sensor switch
must be set at least 15°F above the oil heater
thermostat temperature.
8. Verify that the cooler fan starts and stops in response to
changes in oil temperature. Also check fan rotation. For most A B
coolers, fan rotation is correct when airflow is pushed
through the cooler core as shown in Figure 5-22.
9. If fan does not operate properly, check for defective
electrical components or loose electrical connections. Make
repairs as required. C
10. Reconnect fan leads (if disconnected) before restoring
power when all service is complete.
D
Oil Heaters - Inspect, Clean
Refer to Figure 5-23 during the following steps:
procedures).
being started during the following procedures. Oil pressure
gauge must read zero (0) PSI.
3. Drain all oil from the tank. Follow the procedure earlier in
this chapter. Figure 5–65. Oil Heater Components
4. Inspect and clean the heating elements as follows:
A. Baffle C. Tank
• Remove any carbon build-up or sludge from the B. Heating Elements D. Thermostat
heating elements. (A small amount of carbon on the
element surfaces is normal). Table 5–7. Temperature Settings - Oil Heaters
• Check that heating elements are not bent or cracked.
Verify that they are not touching the tank baffles. Outside Ambient Set Heater
Temperature Thermostat At:
• If heater replacement is necessary, be certain that the
new heater is of the exact same specifications as the Below 40oF (4oC) 90oF (32oC)
original. Contact the Telsmith Service Department for
additional information. Above 40oF (4oC 70oF (21oC)
5. Check that each oil heater thermostat is set to the correct

temperature. Refer toTable 5-6 for temperature settings.
6. Make certain that the cooler temperature switch is set at
least 15°F above the oil heater thermostat temperature. This
will prevent simultaneous operation of the cooler fan and the
oil heater elements.

LUBRICATION SYSTEM SEASONAL Spring (Or Long Term Storage) Start-Up

STORAGE OR LONG TERM STORAGE 1. Remove any loose dirt, snow or ice from the lubrication
system.
Winter Shutdown
2. Check the lubrication system for obvious signs of weather
1. Drain all oil from the lubrication system. See the damage, vandalism, or other problems. Verify that no
procedures earlier in this chapter for draining instructions. animals, rodents, insects etc. are using the oil system as a
2. Refill the oil tank with an oil preservative mixture of four temporary home.
parts new oil to one part oil preservative. Refer to Table 5-7
for oil preservative specifications. IMPORTANT:
3. After adding mixture, attach a tag to the tank to inform The oil preservative mixture is for storage purposes
others that the oil preservative mixture has been added. only. Before returning the crusher to service, completely
drain the oil preservative mixture and replace it with new
oil of the correct specifications.
IMPORTANT:
Do not operate the crusher after the oil preservative 3. Drain the oil preservative mixture from the oil tank. See
mixture has been added. Serious damage to crusher the oil system draining procedures earlier in this chapter.
internal components could result. 4. Fill the tank with new oil of the correct specifications. Oil
4. Without starting the crusher, operate the oil pump for level should be about 3/4 inch (1.9 cm) below the top of the
about 15 minutes to circulate the oil preservative mixture. sight gauge. Refer to Table 5-4 for lubrication system
specifications. See Figure 5-5 for oil capacities. Do not
5. Lock out power to prevent unauthorized crusher operation overfill the tank. Oil level must not be higher than the oil
during the winter shutdown. return screen.
6. Oil systems equipped with water-oil cooler only: 5. Install new oil filter elements. Refer to the procedure
Disconnect the water supply and drain all water from the earlier in this chapter for filter element replacement
cooler. To prevent corrosion damage or freeze-up, be sure the procedures.
cooler is completely drained.
6. Oil systems equipped with water-oil cooler only:
7. Every 14 days: Without starting the crusher, operate the Reconnect the water supply to the cooler. Start the water
oil pump for about 30 minutes to circulate the oil preservative pump (user-supplied) and check for leaks. Be sure there is
mixture. Manually rotate the crusher flywheel and head to return water flow through the water outlet port of the cooler.
ensure that all internal parts remain coated by the mixture.
7. Start the oil pump without starting the crusher. Check the
entire lubrication system for leaks or other obvious problems.
Table 5–8. Oil Preservative Specifications
8. After a few minutes, stop the oil pump and check oil level.
Unit Requirement If the oil level has dropped, add additional oil until the oil
level is about 3/4 inch (1.9 cm) from the top of the sight
Gravity, API @ 60oF 23 gauge.
Viscosity, SUS @ 100oF 550 9. Restart the oil pump. Check all system gauges and
indicators for proper readings. For instructions, refer to the
Flash Point, oF 400 Lubrication System Daily Start-up section earlier in this
chapter.
Film Thickness, mils < 0.1
Humidity Cabinet, days 50+
Viscosity, cSt @ 40oC 110
Notes:
Mixture: 4 parts new oil to 1 part oil preservative.
Refer to Table 5-4 for oil specifications.
Do not operate crusher with oil preservative mixture
in tank. Drain tank and system and circulate new oil
before starting crusher.

NOTES

Chapter 6
Lubrication System Troubleshooting
CONTENTS
Page
LUBRICATION SYSTEM TROUBLESHOOTING SAFETY PRECAUTIONS . . . . . . . 6-2
PRELIMINARY CHECKS & INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
LUBRICATION SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 6-2

1. Alarm Horn Sounds and Crusher Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
2. High Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
3. Low Oil Pressure (Feed Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6
4. Low Oil Flow (Feed Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
5. Low Oil Flow (Return Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6. No Oil Flow Visible Through Countershaft Box Sight Gauge . . . . . . . . . . . . . . . 6-6
7. Relief Valve Bypassing Oil to Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
8. Low Oil Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
9. Oil Cooler Does Not Provide Adequate Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
10. Oil System Loses Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
11. Oil Heater Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
12. Pump Not Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
13. Pump Electric Drive Motor Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
14. Filter Elements Need Replacement Often. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
15. Large Accumulation of Metallic Particles on Oil Return Screen . . . . . . . . . . . 6-11
Oil Pump Flow Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
12/06 6–325
Lubrication System Troubleshooting Operation and Maintenance
LUBRICATION SYSTEM PRELIMINARY CHECKS &

TROUBLESHOOTING SAFETY INSPECTIONS
PRECAUTIONS Make the following checks and inspections before
performing any oil system troubleshooting procedures:
! WARNING !!! • Check that oil level is correct. Add oil if low. Refer to the
procedures in Chapter 5.
Never attempt to service the oil system while it is
operating. Always stop the crusher and lockout/ • Check the entire oil system for leaks. Tighten loose fittings
tagout power before performing any adjustment, as required. Repair or replace any leaking hydraulic
lubrication, maintenance or repair procedures. components or hoses.
Failure to observe the following precautions may • Check that the oil system is securely mounted on a flat,
result in serious personal injury or death! level surface or support structure.
• Be sure to wear appropriate safety devices, such as hard • Be sure proper voltage is connected to the oil pump and
hats, safety glasses and ear protection. alarm. Be sure polarity is correct.
• Be sure to wear or use any additional safety devices • If electrical problems are suspected, have a licensed
required by local, state and federal regulations. electrician inspect and troubleshoot all related electrical
• Use common sense when observing lubrication system circuits and components.
operation during troubleshooting. Be aware of potential
hazards at all times. Avoid contact with rotating parts. LUBRICATION SYSTEM
• Always stop the oil pump and be sure that pressure gauge TROUBLESHOOTING CHART
reads zero (0) PSI before loosening any oil system fittings Refer to Table 6-1 for the lubrication system troubleshooting
or performing service work. Never attempt to lubricate, chart. When indicated in the Corrective Action column, refer
adjust or repair the oil system while the oil pump is on. to the oil system maintenance procedures in Chapter 5. Also
• Avoid contact with hot oil. Hot oil can cause burns. refer to other chapters as noted.
• Never alter, re-adjust or disable any electrical interlocks,

alarms or other safety devices.
• Allow only trained and authorized personnel to perform
oil system troubleshooting procedures
• Allow only licensed electricians to troubleshoot oil system
electrical components and wiring.

Operation and Maintenance Lubrication System Troubleshooting
Telsmith SBS Cone Crusher
Table 6-1. Lubrication System Troubleshooting
SYMPTOMS POSSIBLE CAUSE CORRECTIVE ACTION
1. ALARM HORN SOUNDS AND a. High feed line oil temperature. Alarm is activated when oil temperature rises above 125°F
CRUSHER STOPS (52°C).
Check the feed line oil temperature sensor switch.
If sensor readout indicates over 125°F (52°C), refer to step

2 of troubleshooting.
b. Low feed line oil pressure. Alarm is activated when oil pressure falls below
20 PSI (1.4 bar).
Check the oil pressure sensor switch readout.
If sensor readout indicates under 20 PSI, oil pressure is too

low. Refer to step 3 of troubleshooting.
c. Low feed line oil flow. Alarm is activated when feed line oil flow falls below
the lower limit GPM (L/min) for your model SBS crusher.
Low Limits for each model are as follows:
38/44 - 12 GPM (46 L/min)
52 - 20 GPM (76 L/min)
57 - 25 GPM (95 L/min)
68 - 35 GPM (133 L/min)
Check the oil flow meter. If flow meter indicates a low flow
condition, refer to step 4 of troubleshooting.
d. Loose alarm system connections. Check for loose connections inside the alarm box.
6
(Erractic Alarm Faults Occur)
Check for loose connections at the alarm oil temperature
sensor switch on the feed line or at the DIN rail in the alarm
cabinet.
Check for loose connections at all other alarm inputs and

their respective DIN rail inputs.
Check that all switches and sensors remain tightly installed

and have not loosened.
Check for broken wiring.
Make repairs as required.
Check that Timer Delay is properly adjusted to 5 Seconds

(Refer to Chap. 4 for Time Delay Relay Setting Instructions)
12/06 6–327
2. HIGH OIL TEMPERATURE a. Insufficient oil cooling. See Step 9 of troubleshooting.

(air-oil or water-oil cooler)
Note: If the feed and return line oil temperatures are very
close, it is usually an indication that the oil cooler is not
working.
b. Discharge setting too small. Increase discharge setting. Refer to Chapter 8 of this
manual for additional information.
c. Incorrect oil. Drain oil from oil tank.
Refill tank with new oil of the correct specifications.
Refer to Chapter 5 (Table 5-4) of this manual for oil specifi-

cations.
d. Relief valve bypassing oil to tank. Refer to step 7 of troubleshooting.
e. Fines in material feed causing Minimize or eliminate fines in material feed.

crusher to overwork as it attempts to
Material feed should contain only crushable size material.
crush undersize material.
f. Low oil level. Be sure that tank is full. Oil level must be approximately 3/4
6 inch (1.9 cm) from the top of the sight gauge. Check with
crusher and oil pump OFF.
Add oil if low. Refer to Chapter 5 (Table 5-4) of this manual

for oil specifications.
Check oil tank and hoses for leaks. If leaks are found, make
repairs as required.
g. Internal damage to crusher. Disassemble crusher and check for wear or damage to
parts such as sleeves or bearings. Make repairs as
required.
3. LOW OIL PRESSURE (Feed Line) a. Relief valve bypassing oil to tank. Refer to step 7 of troubleshooting.
b. Pump suction pipe clogged, Check for loose of cracked suction pipe fittings. Tighten or
or pump pickup blocked. replace fittings as required.
Pull oil pump assembly from tank and check suction pipe
for obstructions and pump pickup for blockage. Remove if
present.
c. Pump damaged or worn. Disassemble the pump and check for worn or damaged
gears. Make repairs or replace pump.
6–328 12/06
4. LOW OIL FLOW (Feed Line) a. Crusher feed hose clogged. Check the crusher feed hose for obstructions. Be sure the
hose is not kinked.
Remove obstructions and make repairs as required.
b. Oil Filters restricted. Remove oil filters and check condition. Replace filter ele-
ments if necessary. Check return line filter strainer for signs
of metal buildup (babbit, copper, iron chunks etc.) that could
be causing oil and filter contamination.
c. Low oil level. Be sure that tank is full. Oil level must be approximately 3/4
inch (1.9 cm) from the top of the sight gauge. Check with
crusher and oil pump OFF.
Add oil if low. Refer to Chapter 5 of this manual for oil
specifications.
d. Incorrect oil. Drain oil from oil tank.
Refill tank with new oil of the correct specifications.
Refer to Chapter 5 of this manual for oil specifications.
e. Pump suction pipe clogged, Check for loose of cracked pipe fittings. Tighten or replace
fittings as required. 6
Check suction pipe for obstructions. Remove if present.
Replace pipe if leaking or damaged.
f. Pump damaged. Verify that the pump oil flow is not within specifications by
(Oil flow is weak or intermittent) running the 10 second oil pump test that is detailed at the
back of this chapter.
If pump output is not correct, pull the pump assembly from

the oil tank. Disassemble the pump and check for worn or
damaged parts. Make repairs as required.
g. Relief Valve bypassing oil below 250 Check relief valve for incorrect setting, contamination or
PSI cracking pressure. failure. Replace valve if necessary.
h. Internal damage to crusher Disassemble crusher and inspect.
12/06 6–329
5. LOW OIL FLOW (Return Line) a. Crusher oil return piping clogged Check the crusher oil return piping for obstructions.
or oil excessively cold. See symptom
8. Remove obstructions and make repairs as required.
Check oil heater operation if oil viscosity is too thick (Return
temperature below specification of 50oF (10oC) at sensor).
b. Oil return piping slopes upward from Oil returns to tank by gravity.
crusher drain.
Oil return piping must slope downward from the crusher
drain port to ensure proper flow.
Be sure that the piping has at least a 5 degree downward

slope.
c. Internal damage to crusher. Disassemble crusher and check for wear or damage to
parts such as sleeves and bearings. Check for blocked oil
passages.
6. NO OIL FLOW VISIBLE THROUGH a. Countershaft box feed hose kinked, Verify that the countershaft box feed hose is not kinked or
COUNTERSHAFT BOX SIGHT clogged or leaking. obstructed. Check for leaks.
GAUGE
Inspect the countershaft box sight gauge for damage. Be
sure the gauge orifice is not obstructed.
6 7. RELIEF VALVE BYPASSING OIL a. Crusher feed hose clogged. Relief valve is factory set to open at 250 PSI (17.2 bar).
TO TANK
If oil pressure gauge shows 250 PSI or over, check the
crusher feed hose for obstructions. Make repairs as
required.
Feed line obstructions may also cause the following

conditions:
• Low feed line oil flow
• High oil temperatures
b. Relief valve stuck open or set too If oil is bypassing and oil pressure is under 250 PSI (17.2
low. bar), relief valve is stuck open or set too low. Readjust,
clean, or replace valve as required.
Important: The relief valve must remain set at 250 PSI for
all operating conditions. Do not attempt to raise or lower the
pressure setting. If it is suspected that the pressure setting
has been changed, contact the Telsmith Service Depart-
ment for instructions before making any adjustments.
c. Internal damage to crusher. Disassemble crusher and check for wear or damage to
parts such as sleeves and bearings. Check for blocked oil-
passages. Make repairs as required.
6–330 12/06
8. LOW OIL TEMPERATURES a. Crusher is cold. Oil temperature will drop when the oil is circulated through a
cold crusher that has been shut-down for an extended
period of time.
To warm the oil, run the oil pump with the crusher OFF.
Wait until the oil temperature reaches at least 50°F (10°C)
before starting the crusher. Be sure the oil heaters are
switched ON.
Note: In cold climates, it is recommended that the oil pump

and heaters remain switched ON during crusher shut-down
periods. The circulating warm oil will allow the crusher to be
more quickly re-started at the beginning of the next shift.
b. Oil heaters not working. Check that all oil heaters are properly connected to a power
source of the correct voltage.
Be sure that heaters remain connected to power, even

when crusher is off.
Check that oil heater thermostats are set to between 70°F

(21°C) and 100°F (38°C).
Be sure the thermostat on each of the oil heaters is set at

the same temperature.
Check for carbon build-up on elements. Clean as required.

Check for defective thermostats or burned-out elements.
6
c. Oil heater thermostats set too low. Raise the temperature of the oil heater thermostats as
required. To ensure even heating, be sure the thermostat
on each oil heater is set to the same temperature.
The oil heater thermostats are normally set at 70° to 90°F

(21° to 32°C) depending on outside ambient temperature.
They can be set up to 100°F (38°C) for especially cold
climates. Refer to Chapters 4 and 5 for additional
information.
12/06 6–331
8. LOW OIL TEMPERATURES d. Water cooler providing too much Reduce water flow through the water cooler.
(Continued) cooling.
(oil systems equipped with water-oil
cooler only)
e. Oil cooler temperature switch set too Check that the oil cooler temperature sensor switch is set to
low. the proper temperature.
(oil systems equipped with air-oil
cooler only) Refer to Chapters 4 and 5 for temperature settings.
Note: Be sure that the cooler temperature sensor switch is

set at least 15°F above the oil heater thermostat setting.
This temperature differential will prevent the heater ele-
ments and the cooler fan from operating simultaneously.
f. Air-oil cooler fan operates Check the oil cooler temperature sensor switch setting as
continuously. described in step 8e.
cooler only) Check wiring between the switch and the fan contactor. Be
sure all connections are correct.
Check the oil cooler temperature sensor switch for proper

operation. Replace switch if defective.
g. Additional oil heaters needed. Additional oil heaters may be installed to provide increased
heating capacity for very cold climates.
6 Contact the Telsmith Service Department for additional

information.
6–332 12/06
9. OIL COOLER DOES NOT a. Unusually high outside ambient If outside ambient temperatures are very hot, consider
PROVIDE ADEQUATE COOLING temperatures. increasing oil cooling capacity as follows:
If equipped with water-oil cooler:

• Increase water flow
• Install an additional water-oil cooler
• Add an air-oil cooler
If equipped with air-oil cooler:

• Install an additional air-oil cooler
• Add a water-oil cooler
• Shade the cooler from direct sunlight
Contact the Telsmith Service Department for additional

information.
b. Air-oil cooler fins covered with dirt. Clean dirt from fins.
cooler only)
c. Air-oil cooler obstructed by walls, Remove obstructions or relocate cooler.

structures or equipment.
cooler only)
d. Air-oil cooler fan turning in the wrong Reverse fan direction.

direction.
cooler only)
6
e. Air-oil cooler temperature sensor Check that the oil cooler temperature switch is set to the
switch set too high. proper temperature.
cooler only) Refer to Chapters 4 and 5 for temperature settings.
Note: Be sure that the cooler temperature switch is set at

least 15°F above the oil heater thermostat setting. This
temperature differential will prevent the heater elements
and the cooler fan from operating simultaneously.
f. Air-oil cooler fan not working. Check wiring between the sensor switch and the fan con-
(oil systems equipped with air-oil tactor. Be sure all connections are correct. Refer to Ch 4.
cooler only)
Check the air-oil cooler sensor switch for proper operation.
Replace switch if defective.
Check that the fan rotates freely. Test the fan motor for
proper operation. Replace if defective.
g. Air-oil cooler passages clogged. Flush the cooler to clean-out clogged passages.
cooler only)
h. Water flow through water-oil cooler Increase water flow through cooler.
too low.
(oil systems equipped with water-oil
cooler only)
i. Water-oil cooler passages clogged. Flush the cooler to clean-out clogged passages. Clean out
(oil systems equipped with water-oil any debris.
cooler only)
12/06 6–333
10. OIL SYSTEM LOSES OIL a. Tank leaking. Inspect the tank and all tank fittings for leaks. Make repairs
as required.
b. Worn hoses and/or loose fittings. Check all hoses and fittings for leaks. Tighten fittings or
make repairs as required.
c. Pump leakage at adapter plate on Pump adapter gasket leaking or pump adapter not tightly
top of tank. mounted to adapter mounting plate. Tighten fasteners or
replace gasket as needed.
d. Crusher piston rings worn. Two large piston rings are used to control oil flow within the
crusher. Internal oil leakage will occur if either of the piston
rings is worn or cracked.
If internal oil leakage is suspected, disassemble the crusher

and replace piston rings as required.
11. OIL HEATER FAILURE a. Carbon build-up on heater elements. Periodically clean and inspect heater elements to prevent
premature failures.
b. Heater elements not submerged in Always disconnect power to heaters when tank is drained.
oil.
Always disconnect power to heaters during oil changes and
seasonal storage.
6 c. Heater elements touching tank When installing new oil heaters or performing tank
baffles. maintenance, be careful not to bend the heater elements.
They must not touch the tank baffles.
d. Heater thermostat bad. Have an electrician verify thermostat is operational.

Replace if required.
12. PUMP NOT PUMPING a. Pump gears turning in the wrong Reverse pump drive motor polarity and check oil flow.
direction.
See Chapter 4 of this manual for additional information.
b. Pump suction pipe clogged. Check for loose or cracked suction hose fittings. Tighten or
replace fittings as required.
Check suction pipe for obstructions. Remove if present.
c. Low oil level. Be sure that tank is full. Oil level must be approximately
3/4 inch (1.9 cm) from the top of the sight gauge. Check
with crusher and oil pump OFF.
Add oil if low. Refer to Chapter 5 of this manual for oil

specifications.
d. Incorrect oil. Drain oil from tank. Refill tank with new oil of the correct
specifications.
Refer to Chapter 5 of this manual for oil specifications.
e. Pump damaged. Disassemble the pump and check for worn or damaged
parts such as worn or pitted gears. Make repairs as
required.
6–334 12/06
13. PUMP ELECTRIC DRIVE MOTOR a. Pump drive motor over amping. Motor is overloaded due to oil pump problem, extremely
NOISY cold oil (high viscosity) or incorrect type oil. Check oil type
as specified in Chapter 5. If oil is correct, check oil pump for
damage or obstruction.
b. Pump motor is experiencing power Check generator power output on generator powered units.
spikes, dips or surges.
Check for power line fluxuations on non-generator units.
Correct input power problems by installing line filters or
using a power conditioning transformer on incoming power.
Check motor starter protector for correct operation. Replace

if necessary.
14. FILTER ELEMENTS NEED a. Breathers dirty or clogged. Clean or replace tank breather as required.
REPLACEMENT OFTEN
Clean or replace countershaft box breather as required.
SLUDGE AT BOTTOM OF OIL TANK
Important: Breathers must remain clean to prevent the oil
system from drawing in dust through the crusher seals.
b. Oil poured from an unclean Be sure that oil container is clean to prevent dirt and other
container. harmful contaminants from entering the oil system.
c. Tank cover not tight against tank. Inspect the gasket between the tank and the tank cover.
Replace if worn or missing.
Be sure that the tank access cover remains tightly installed 6

at all times except when it must be removed for mainte-
nance.
Important: Be especially careful that dust or dirt does not

enter the tank while the tank cover is removed.
d. Pump suction pipe is drawing sludge Check the pump suction pipe for obstructions.
up into filters.
Drain, clean and refill oil tank. Pull pump assembly and
clean suction pipe and pump intake port.
15. LARGE ACCUMULATION OF Internal damage to crusher. Iron particles may indicate worn gear teeth or bearing
METALLIC PARTICLES ON OIL rollers.
STRAINER RETURN FILTER
Bronze, lead or babbitt particles may indicate worn or
cracked sleeves. In some cases, bronze particles may also
indicate worn bearings.
Disassemble crusher and check for worn or damaged parts.

12/06 6–335
Oil Pump Flow Testing

1. Verify that the oil level in the oil tank is correct (Refer to
Chapter 4, Fig 4-20) before starting the test. If oil level is low,
add additional oil of the correct specification, until oil level is C
3/4’ (1.9 cm) from top of gauge. If oil tank is overfull, remove
the oil tank access cover and siphon oil until the correct level
is reached. Both a low or overfull condition could effect pump
performance and possibly damage the crusher.
2. Lockout/tagout power to the crusher drive and the oil
pump starter. (Refer to Chapter 1 for complete lockout/tagout B
procedures).
3. Verify that the oil pressure reading on the oil pressure
sensor switch has dropped to zero (0) PSI (Fig. 6.1) A
0 0 Figure 6–67. Oil Feed Hose Tee Fitting

Mode/Enter Set
A
A. Oil Feed Line C. Main Frame Oil Input Port
B. Tee Fitting
5. Obtain two containers capable of holding at least 10

B
C gallons of fluid (Fig. 6-3) and a stop watch. Place the oil feed
line in one container.
A B
D Figure 6–68. Oil Pump Bleeding
A. Oil Feed Line B. 10 gallon (minimum) containe

Figure 6–66. Oil Pressure Switch
6. Re-establish power to the oil pump motor starter. Start the
pump and run oil into the first container until a steady flow is
A. Oil Pressure Sensor C. Oil Pressure Sensor Switch established. Switch the line to the 2nd empty container and
Reading D. Manifold
B. Oil Feedline time the oil flow for exactly 10 seconds. Remove the line
Temperature Sensor immediately when 10 seconds is reached and return the line
Switch
to the first container. Shut off the pump and lock out power to
4. Disconnect the oil feed line at the tee fitting located at the the motor starter.
main frame oil input port (Fig. 6-2).

7. Measure the amount of oil collected in the second bucket

and compare the amount to the 10 second Gallon Per Minute
(GPM) measurement in Table 6.2.
Table 6-2. SBS Crusher Oil Pump Flow Rates
60 second 10 Second
Model
Flow Rate Flow Rate
38/44 12 GPM (45.4 LPM)( 2 G (7.5 L)
52 20 GPM (75.7 LPM) 3.33 G (12.5 L)
57 25 GPM (94.6 LPM) 4.1 G (15.5 L)
68 35 GPM (132.5 LPM) 5.8 G (21.9 L)
8. If the flow rate for your pump is significantly lower than

the standard flow rate (20% or more) a pump problem exists
and the pump (or drive motor) should be rebuilt or replaced.
9. If your pump is within specification, refill the oil tank to
the full mark and re-establish power to the oil pump starter
motor and the crusher.
10. Reinstall the feed line at the main frame tee fitting (Fig 6-
2).
11. Start the oil pump and circulate oil thru the crusher.
Remove the oil tank access cap and check whether oil is
flowing out the full circumference of the oil return strainer. If
not, a blockage or other problem is present in the return line
or in the crusher.


Chapter 7
Hydraulic System Overview
CONTENTS
Page
HYDRAULIC POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
HYDRAULIC SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Hydraulic System Overview Operation and Maintenance
HYDRAULIC POWER UNIT
D
H
B
G
Figure 7–69. Hydraulic Power Unit

A – Control Panel B – Hydraulic Pump C – Pressure Gauge D – Access Cover
E – Sight Gauge F – Filler Cap G – Reservoir H – Motor

Operation and Maintenance Hydraulic System Overview
B A
(52-68 SBS HPU Shown)
Figure 7–71. Control Valves and Manifold

Model 38/44 A – Hydraulic Control Valves
B – Quick Disconnect Fittings
(Number of fittings may vary by model)
B
A
Models 52 – 68
Figure 7–70. Hydraulic Oil Filters

A – Filter Indicators B – Hydraulic Oil Filters

HYDRAULIC SYSTEM DESCRIPTION

The hydraulic system operates these main functions:
• CRUSH (Hydraulic Relief/Clamping): Applies
clamping pressure during crushing. Automatically allows
passage of most uncrushable objects without damage to
the crusher.
A
• CLEAR (Hydraulic Clearing): Allows the upper frame
to be raised manually for clearing jammed material or
especially large uncrushable objects.
B
• EXTRACT (High Speed Extract): Allows the support
bowl to be rapidly unscrewed from the upper frame to
facilitate liner changes.
! CAUTION C
Selector Switch will return to CRUSH when

selector switch is released from any other
position. When switch returns from CLEAR, the
Upper Frame will lower. Operator must hold the D
selector switch in CLEAR when removing
jammed or over sized material or objects. When
safety spacers are used during a clearing
operation, special precautions must be taken to
prevent damage to safety spacers or the main
frame that could occur if the the selector switch
was released and the unit returned to CRUSH
mode.
• START: Starts the power unit pump motor.
• CLOSE: Rotates support bowl clockwise in either
Figure 7–72. Hydraulic Control Console
EXTRACT (High Speed Extract) or CRUSH to reduce
close side setting. A – Main Disconnect Switch B – Selector Switch
C – Controls D – Digital Display
• OPEN: Rotates support bowl counterclockwise in either
EXTRACT (High Speed Extract) or CRUSH to open
close side setting.
• STOP: Stops power unit pump motor.
• MANUAL/AUTO: Switches power unit control for
operation of OPEN or CLOSE directly at the power unit
control panel.
NOTE:
In AUTO mode, Open and Close will only work remotely
at operator interface panel (or PLC).
If in MANUAL mode, power unit setting adjustments will
not work remotely at operator interface panel (or PLC).

Operation and Maintenance Hydraulic System Overview
The hydraulic system also includes the following additional

features:
• Hydraulic Lock/Unlock: A series of hydraulic cylinders
located above the upper frame automatically locks the
support bowl in-place when the CRUSH function is
activated. During discharge setting adjustments, these
cylinders are partially de-energized to allow rotation of
the support bowl.
• Hydraulic Power Rotation: Power rotation is used to turn
the support bowl assembly for discharge setting
adjustments. For models 38 and 44 crushers, one power
rotator is used, for models 52, 57, and 68 crushers, two
power rotators are used. The discharge setting can be
easily changed at any time by depressing and holding
either the OPEN or CLOSE push buttons on the hydraulic
control console. Stopping the crusher is not necessary.
• Hydraulic Anti-Spin: The anti-spin unit (optional)
automatically prevents the crusher head from turning with
the eccentric when the crushing chamber is empty or
underfilled. This feature helps reduce liner wear. The anti-
spin unit is activated at all times whenever the power unit
is switched on.
For hydraulic system installation and operation instructions,
please refer to Chapter 8. See Chapter 9 for hydraulic system
maintenance instructions. Hydraulic system troubleshooting
instructions are located in Chapter 10.
Figure 7–74. Power Rotator
A A
Figure 7–73. Hydraulic Locking Cylinders

A – Locking Cylinder

Figure 7–75. Hydraulic Relief Cylinder Model 38
Figure 7–76. Hydraulic Relief Cylinder Models 44–68

Chapter 8
Hydraulic System Installation and Operation
CONTENTS
Page
SHIPMENT DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
HYDRAULIC SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
HYDRAULIC SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Hydraulic Relief/Clamping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulic Clearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Removing Jammed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Hydraulic Extract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Discharge Setting Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
DIGITAL DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Resetting the Digital Display to Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Measuring Liner Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Proximity Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Connecting the Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Proximity Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

Hydraulic System Installation and Operation Operation and Maintenance
SHIPMENT DETAILS HYDRAULIC SYSTEM INSTALLATION

The hydraulic power unit is normally shipped separately from 1. Stationary crushers only: Place the power unit on a firm
the crusher. It must be installed and connected after the and level surface near the crusher. Secure the power unit with
crusher is mounted on its foundation. bolts, washers and isolation mounts (shipped loose).
If the crusher is mounted on a Telsmith portable plant, the 2. Portable plants only: Remove the shipping brackets
power unit is usually pre-installed on the plant chassis. (painted red) at all four corners of the power unit. Save the
However, some additional wiring and final assembly may be shipping brackets for future use.
required.
3. Connect the hydraulic hoses to the quick-disconnect
Some hydraulic system components may be shipped couplers on the back of the power unit as shown in Figure
separately from the power unit. If present, these items will be 8-1. All hydraulic hoses use quick disconnect couplers to
located inside crates or fastened to pallets. Refer to the bill- simplify hookup.
of-lading or packing list for a complete description of all
items included in the shipment.
C
A G D
B
C
E
A
F
D E
Figure 8–77. Power Unit Hydraulic Hose Connections
A. Locking Cylinder Feed Hose C. Relief Cylinder Hose (Bottom) E. Power Rotator Hose (Bottom) G. Lock Cylinder Return Hose
B.Relief Cylinder Hose (Top) D. Anti-Spin Port Hose (T-Port ) F. Power Rotator Hose (Top)

Operation and Maintenance Hydraulic System Installation and Operation
! WARNING
Failure to properly install and connect electrical
equipment may result in a dangerous electrical
shock hazard. All connections must be made in
accordance with the National Electric Code and
any applicable local codes. Be sure all electrical
A work is done by a licensed electrician.
5. Power units equipped with digital display only:
Connect the proximity switch cable to the receptacle on the
underside of the hydraulic control console. Refer to Figure 8-
8 later in this chapter.
6. Connect the hydraulic system pressure switch (PS-1) to
the crusher motor starter circuit. Use terminals 13 and 14
inside the hydraulic control console. Refer to Appendix D for
B the hydraulic system electrical schematic.
7. Make all remaining electrical connections to the hydraulic
control console as shown in Appendix D.
8. Jog the hydraulic pump motor by quickly pressing
START then STOP. Verify that the motor fan rotates in the
same direction as the arrow on the fan housing. Reverse
electrical leads if direction of rotation is incorrect.
See Figure 8-3.
Figure 8–78. Reservoir Sight Gauge
A. Full Mark B. Add Oil
4. Check the oil level in the hydraulic reservoir sight gauge.

Refer to Figure 8-2. The oil level must be up to the BLACK
line at the top of the gauge. Add oil if required. Refer to
Chapter 9 for hydraulic oil specifications and capacities.
A
! WARNING
Always lock out power and tag controls before
making any electrical connections. Failure to Figure 8–79. Pump Motor Rotation
observe this precaution may result in serious
personal injury or death. A. Hydraulic Pump Motor B. Rotation Arrow

HYDRAULIC SYSTEM OPERATION 1. Move the hydraulic cabinet disconnect switch (A, Fig. 8-
4) to the ON position.
Hydraulic Relief/Clamping 2. Verify that the self centering function selector switch (B,
Activate the hydraulic relief/clamping function as follows. Fig. 8-4) is in the center (CRUSH) position.
.
ON
OFF
C
O
A
Crush
Clear Extract Start Close
High Spd F
Manual Auto Stop Open
D G
Figure 8–80. Control Panel Functions
A. Disconnect Switch C. Start Button E. Stop Button G. Discharge Setting Open Button
B. Function Selector Switch D. Manual/Auto Selector Switch F. Discharge Setting Close Button H. Counter Control

6. Crushing may begin immediately after proper hydraulic

! CAUTION pressure is indicated.
If the function selector switch does not self
center to the CRUSH position but remains in the
CLEAR or EXTRACT HIGH SPEED position, the
switch is defective and must be replaced or
repaired before continuing crusher operation.
3. Move the manual/auto switch to MANUAL or AUTO as
required (see note below).
NOTE:
Unless the crusher discharge setting is being regulated
by a programmable controller or other external source,
the manual/auto switch should remain in the MANUAL
position at all times.
4. Press the START push button. The hydraulic pump will
start. A
Models 52, 57, 68
5. Verify that the hydraulic pressure gauge (Fig 8-6)
indicates approximately 2200 PSI (151 bar) [3000 PSI (207
bar) on Model 57 only].
A
NOTE:
The hydraulic power unit is equipped with a hydraulic ON
OFF
interlock switch (Fig 8-5). If the pump will not produce a

CRUSH START CLOSE
CLEAR EXTRACT
HIGH
SPEED
minimum pressure of 900 psi (69 bar), the crusher will MANUAL AUTO
STOP OPEN
not operate. Refer to troubleshooting procedures in

Chapter 10 if a low pressure condition is suspected.
Models 38/44
Figure 8–82. Pressure Gauge Location
A. Pressure Gauge
A
Figure 8–81. Hydraulic Interlock Switch
A. Interlock Pressure Switch and Gauge

Hydraulic Clearing
Use the following procedure to clear the crushing chamber of
! WARNING
jammed or oversize material. Refer to Figure 8-4 during the Before lowering the upper frame, be sure no
following steps: people are working on or inside the crusher.
Keep all personnel away from the crusher while
1. Stop the crusher. the frame is being lowered. Failure to observe
2. Lockout/tagout power to the crusher drive and to all feed this precaution may result in serious personal
and discharge devices. (Refer to Chapter 1 for complete injury or death!
lockout/tagout procedures). 8. When clearing is complete, move the function selector
switch to CRUSH. Wait until the upper frame is completely
IMPORTANT: lowered and pulled tight against the main frame before
starting the crusher.
The crusher must be stopped during hydraulic clearing.
Never attempt to operate the crusher while hydraulic
clearing is in progress.
3. Be sure no personnel are on or near the crusher.
! WARNING
Function Selector Switch (B, Fig. 8-4) is a self
centering switch that returns to the center
(CRUSH mode) when released. When operating
i n t h e C L E A R m o d e , t h e o p e r a t o r mu s t
continuously hold the switch in the CLEAR
position to prevent the upper frame from
returning to the CRUSH mode and beginning to
lower the upper frame. Failure to maintain the
CLEAR position could result in unexpected
lowering of the upper frame and danger to
personnel working on or near the crusher.
4. Move the function selector switch to CLEAR and
continue to hold the switch in this position. The upper frame
will begin rising slowly. One side of the frame may rise faster
than the other. This is normal and will not damage the crusher.
5. Allow several minutes for the upper frame to rise. Wait
until all cylinders are fully extended and the upper frame is
raised approximately 5-1/2 inches (140mm) above the main
frame.
6. In most cases, jammed or oversize material will pass
completely through the crushing chamber without any
manual effort. If any material remains lodged in the crushing
chamber after the upper frame is fully raised, refer to the
paragraph Removing Jammed Material later in this chapter.
7. If present, clean up any spilled material or debris from
platforms, walkways and other areas near the crusher.

Removing Jammed Material

Use the following procedure whenever jammed or oversize
! WARNING
material must be manually removed from the crushing Be certain that the upper frame is supported by
chamber. safety spacers or hardwood blocking before
e n t e r i n g t h e c r u s h i n g cha m b e r. S e r i o u s
1. Stop the crusher. Lockout/tagout power to the crusher personal injury or death could result if the frame
drive and to all feed and discharge devices (Refer to Chapter lowers unexpectedly on persons working inside
1 for complete lockout/tagout procedures). the crusher.
2. Fully raise the upper frame. Follow the procedure in the 4. Make certain the function selector switch has returned to
Hydraulic Clearing paragraph earlier in this chapter. When the CRUSH (center) position. Press the Start button. Lower
the upper frame has extended fully, press the STOP button (E, the upper frame until it is supported by the safety spacers.
Fig. 8-4). Then press the STOP button.
3. Place a safety spacer (provided loose with crusher) around
each thrust pin, between the upper and main frames. See ! CAUTION
Figure 8-7. If safety spacers are unavailable, place evenly-
spaced hardwood blocking between the upper and main When lowering the upper frame onto the safety
frames. spacers, make certain the STOP function is
activated at the point that the upper frame first
contacts the safety spacers. Continuing to apply
downward pressure could crush the spacers and
damage the upper frame.
5. Lockout/tagout power to the hydraulic control console.
Be sure that power to the crusher drive and to all feed and
discharge devices remains locked-out and tagged.
A
B
C
D
! WARNING
Install SAFETY SPACER around
each thrust pin.
Figure 8–83. Safety Spacers

A — Upper Frame B — Safety Spacer C — Thrust Pin D — Lower Frame

! WARNING ! CAUTION
Use a rock hook, breaker bar or grappling hook If you are using the EXTRACT HIGH SPEED
to remove jammed material. Keep your entire mode to fully open or remove the support bowl,
body, including hands and feet, clear of any hydraulic pressure must be released from the
falling material. Do not work directly under the locking cylinders. To prevent damage to the
crusher discharge openings. support bowl threads or the locking nut ring
threads, remove the locking cylinder hydraulic
6. From the top of the crusher, carefully remove any jammed
feed hose prior to using the Extract High Speed
material lodged inside the crushing chamber.
mode. Refer to Chapter 3 in the Silver Bullet
7. Carefully remove any jammed material from the crusher Series Wear Liner Replacement Manual for
discharge chute and conveyor. If present, carefully remove complete support bowl removal instructions
any jammed material lodged inside the lower portion of the
The Extract High Speed function is intended only for use
crusher.
during maintenance and repair procedures. It should not be
8. Clean-up any spilled material or debris from platforms, activated while crushing is in progress. Refer to the Silver
walkways and other areas near the crusher. Bullet Series Wear Liner Replacement Manual for complete
support bowl removal instructions.
9. After the crushing chamber is completely free of all
material, move the function selector switch to CLEAR and
hold in this position. Depress the START button and raise the Discharge Setting Adjustment
upper frame a small amount. Remove the safety spacers or The discharge setting may be adjusted while crushing, or
hardwood blocking. when the crusher is stopped. Make adjustments as described
in the following steps. Refer to Table 8-1.
! WARNING 1. Make certain the function selector switch is in the
Before lowering the upper frame, be sure no CRUSH (center) position.
people are working on or inside the crusher. 2. Crushers not equipped with remote controls: Check that
Keep all personnel away from the crusher while the manual/auto switch is in the MANUAL position.
the frame is being lowered. Failure to observe
this precaution may result in serious personal 3. Depress and hold the OPEN or CLOSE button until the
injury or death! ring gear near the top of the crusher begins to rotate. Verify
that the gear turns in the desired direction. On some crushers,
10. Check that the function selector switch has returned to the it will be necessary to depress and hold the button for
CRUSH (center) position. Wait until the upper frame has approximately 15 to 20 seconds until rotation begins.
completely lowered and pulled tight against the main frame
before activating the STOP button. • Clockwise rotation (CLOSE) will decrease the size of the
crushed material.
Hydraulic Extract • Counterclockwise rotation (OPEN) will increase the size
The EXTRACT HIGH SPEED mode allows the support bowl of the crushed material.
assembly to be opened at a faster than normal speed. After the 4. Repeat step 3 as required until the desired discharge
assembly becomes unthreaded from the upper frame, it can setting is achieved.
then be completely removed using a crane or hoist of suitable
capacity.

Table: 8-9
Discharge Setting Adjustment
Required Support Bowl Movement

Amount of
(Equivalent Number of Gear Teeth Rotation)
Adjustment
Required
Model 38 Model 44 Model 52 Model 57 Model 68
1/16 8 9 9 11.7 9.5

3/32 12 — — — —
1/8 16 17 19 23.3 18.9
5/32 20 — — — —
3/16 24 26 28 35.0 28.4
7/32 28 — — — —
1/4 32 34 37 46.7 37.8
9/32 36 — — — —
5/16 40 42 47 58.3 47.3
11/32 44 — — — —
3/8 48 51 56 70.0 56.7
13/32 51 — — — —
7/16 56 59 65 81.7 66.2
15/32 60 — — — —
1/2 64 68 75 93.3 75.7
17/32 66 — — — —
9/16 72 76 84 105.0 85.1
19/32 76 — — — —
5/8 80 85 93 116.7 94.6
21/32 84 — — — —
11/16 88 93 102 128.3 104.0
23/32 92 — — — —
3/4 96 102 112 140.0 113.5
25/32 100 — — — —
13/16 104 110 121 151.7 122.9
27/32 108 — — — —

Table: 8-9
Discharge Setting Adjustment
Required Support Bowl Movement

Amount of
(Equivalent Number of Gear Teeth Rotation)
Adjustment
Required
Model 38 Model 44 Model 52 Model 57 Model 68
1/16 8 9 9 11.7 9.5

3/32 12 — — — —
7/8 112 119 130 163.3 132.4
29/32 116 — — — —
15/16 120 127 140 175.0 141.9
31/32 124 — — — —
1 inch 128 136 149 186.7 151.3
1-1/16 — 144 158 198.3 160.8
1-1/8 — 153 168 210.0 170.2
1-3/16 — 161 177 221.7 179.7
1-1/4 — 170 186 233.3 189.2
1-5/16 — 178 196 245.0 198.6
1-3/8 — 187 205 256.7 208.1
1-7/16 — 195 214 268.3 217.5
1-1/2 — 204 223 280.0 227.0
1-9/16 — 212 233 291.7 236.4
1-5/8 — 221 242 303.3 245.9
1-11/16 — 229 251 315.0 255.4
1-3/4 — 238 261 326.7 264.8
1-13/16 — 246 270 338.4 274.3
1-7/8 — 255 279 350.0 283.7
1-15/16 — 263 287 361.7 293.2
2 — 272 298 373.4 302.6

DIGITAL DISPLAY
Figure 8–84. Digital Display
DIGITAL DISPLAY 2. Be sure that power is connected to the hydraulic control

console.
Some crushers are equipped with an electronic digital display
(optional equipment). Refer to Figure 8-8. The display 3. Check that the manual/auto switch is in the MANUAL
indicates the crusher discharge setting as measured at the position.
closed side of the crushing chamber. It is operational
whenever electrical power is connected to the hydraulic NOTE:
control console.
The Manual/Auto switch should remain in the MANUAL
A proximity sensor is mounted opposite of the pinion gear on postion at all times unless the crusher discharge setting
one of the power rotators. The sensor counts the gear teeth as is being regulated by a programmable controller or other
the gear turns, providing a reference for the display. An external source.
electrical cable connects the sensor to the hydraulic control
console. 4. Make certain the function control knob is in the CRUSH
(center) position.
Resetting the Digital Display to Zero 5. Depress and hold the CLOSE button until the ring gear
To ensure accurate readings, the digital display must be reset near the top of the crusher begins to rotate. On some crushers,
whenever liner replacement has been performed. Reset the it will be necessary to depress and hold the button for
display as described in the following steps: approximately 15 to 20 seconds until rotation begins.

drive motor (Refer to Chapter 1 for complete lockout/tagout
procedures).

6. Continue to depress and hold the CLOSE button until the 7. To ensure accurate wear measurements, always reset the
liners (mantle and concave ring) make contact with each digital display immediately after replacing the liners. Refer to
other. Release the button immediately when contact is made. the procedure earlier in this chapter.
The ring gear near the top of the crusher will turn as the liners
come together.
IMPORTANT:
To prevent damage to crusher, never attempt to
7. Depress and release the two reset keys measure liner wear during crusher operation.
on the display at the same time. The display should now read
“0.000”.
8. Depress and hold the OPEN button until the desired
discharge setting is shown on the display. Measurements will
be shown in thousandths of an inch.
9. The crusher may be restarted after the desired discharge
setting is obtained.
IMPORTANT:
To prevent damage to the crusher, never attempt to
reset the digital display to zero while the crusher is in
operation.
Measuring Liner Wear

Liner wear should be measured periodically to ensure that the
liners have not exceeded their allowable wear limits.
Determine the amount of liner wear as described in the
following steps:
drive motor (Refer to Chapter 1 for complete lockout/tagout
procedures).
2. Be sure that power remains connected to the hydraulic
control console.
3. Move the manual/auto knob to MANUAL. Move the
function control switch to CRUSH.
4. Depress and hold the CLOSE button until the liners
(mantle and concave ring) make contact with each other.
Release the button immediately when contact is made.
5. Observe the value shown on the digital display. If no wear
has occurred since the last time the display was reset, the
display will read “0.000”. If the display shows a negative
value, it is an indication that some wear has occurred. Always
record the negative value (if shown) for future reference
before resetting the display.
6. To determine the total amount of liner wear that has
occurred over time, add the most recent negative value
measurement to all previous negative value measurements
that were recorded earlier. This combined measurement is the
total amount of wear.

Proximity Sensor Adjustment 4. Using a feeler gauge, check the gap between the sensor
and the closest gear tooth. The air gap measurement should be
If it is suspected that the digital display is not providing
approximately 0.040 to 0.080 inch.
accurate readings, inspect the proximity sensor as described
in the following steps: 5. If the air gap measurement is not within acceptable limits,
loosen the sensor adjusting nuts and adjust the sensor position
as required. Check the air gap measurement again after
drive motor and to the hydraulic control console (Refer to
tightening the nuts.
Chapter 1 for complete lockout/tagout procedures).
6. When adjusting the sensor gap make certain the “A”
2. Remove the cover over the power rotator. Refer to Chapter
machined in the sensor body continues to point left (Fig. 8-9)
9 for cover removal instructions. The pinion gear and sensor
when viewed from the top.
will be visible. See Figure 8-7.
3. Verify that the sensor is properly aligned as shown in the
figure below. Check that the sensor is tightly secured.
IMPORTANT:
Reinstall the cover over the power rotator after making
any inspections or adjustments.
Note: Power rotator cover is

removed for illustrative purposes only
Figure 8–85. Proximity Sensor Details
A “A” must be assembled in B — Check for any burrs or C — Air gap must measure
orientation shown. buildup on sensor or gear between 0.40 to 0.80” (10.16
teeth. (Remove if present.) to 20.32 mm)

Connecting the Proximity Sensor Proximity Sensor Trouble-Shooting

The proximity sensor is wired to the hydraulic control If the Displayed Closed Side Setting accuracy is diminished:
console via an electrical cable.
1. Verify that there are no burrs on the pinion gear, it is
1. Lockout/tagout power to the hydraulic control console acceptable for this to occur as the gears mesh and wear in.
(Refer to Chapter 1 for complete lockout/tagout procedures). Verify that the machine is locked out and the hydraulic unit is
in the off position and locked out and carefully remove the
2. Connect the proximity sensor cable to the receptacle on
built up burrs on the power rotator pinion gears.
the bottom of the hydraulic control console as shown in
Figure 8-10. 2. Verify that the sensor has not picked up any foreign
metallic material. The sensor contains magnetic poles and
this may impact the ability of the sensor to accurately count
IMPORTANT: the gear teeth.
Always disconnect power to the hydraulic control
console before connecting or disconnecting the 3. Verify the Proximity Sensor Mounting Bracket is secure
proximity sensor cable. Failure to obser ve this and the sensor adjustment has been verified per the Proximity
precaution may result in damage to the proximity sensor Sensor Adjustment section discussed earlier.
or digital display. 4. Verify the sensor cable is tightened securely to the
hydraulic power unit console.
5. Check two control relays for proximity sensor. Verify that
ON relays have not come loose or that relay prongs are not bent.
OFF
CRUSH
CLEAR EXTRACT
HIGH
SPEED
START CLOSE Digital display will not show correct calibration if proper
contact is not made at all prongs.
MANUAL AUTO
STOP OPEN
6. If improper reading is obtained, system programming

may be incorrect.
B
Figure 8–86. Connecting the Proximity Sensor Cable
A. Proximity Cable B. Console Receptacle

Chapter 9
Hydraulic System Maintenance
CONTENTS
Page
HYDRAULIC SYSTEM MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
HYDRAULIC SYSTEM MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . 9-6
DEPRESSURIZING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
HYDRAULIC POWER UNIT MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . 9-8

Hydraulic Oil Level - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Hydraulic Oil Filter Indicators - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Hydraulic Oil Filter Element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Filler Cap Assembly - Inspect/Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Hydraulic Reservoir - Drain/Clean/Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Hydraulic Pump Motor - Inspect/Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Oil Cooler - Clean/Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Solenoid Coil - Replace - Type “A” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Solenoid Coil - Replace - Type “B” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
RELIEF CYLINDER MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17

Relief Cylinder - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Cylinder Coupling - Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Relief Valve - Replace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
POWER ROTATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Gear Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Gearbox Oil Level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Gearbox Oil - Drain/Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
ANTI-SPIN AIR BLEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
BUTTRESS THREAD LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Hydraulic System Maintenance Operation and Maintenance
HYDRAULIC SYSTEM MAINTENANCE

SCHEDULE
Table 9:
Before Crusher Start-up
After Crusher Start-up
As Required
Monthly
Weekly
Yearly
INSPECT, LUBRICATE OR SERVICE AS FOLLOWS:
Remove built-up dirt and dust from relief cylinder clevises and couplings. •
Grease relief cylinder couplings. •
Inspect the entire hydraulic system for leaks or other obvious problems. •
Check oil level in hydraulic reservoir. •
Check that both hydraulic filter indicators are GREEN. • •

(Note: Check with power unit in CRUSH mode.)
Check the relief hydraulic pressure gauge. Verify that pressure is 2200 • •
psi ± 50 psi (3000 psi ± 50 psi Model 57).
Remove any built-up dirt from around the power rotator housings. •
Inspect the power rotators for obvious damage or wear. Check for oil •
leaks.
Check oil level in the power rotator gearboxes. •
Grease the buttress threads. •
Unlock the support bowl and rotate it back-and-forth several times. •
Clean the hydraulic reservoir filler cap. Replace if clogged. •
Drain and refill the hydraulic reservoir. Replace both filter elements. •
Drain and refill the power rotator gearbox(es). •
Replace filter element if indicator turns RED. •

Lubricate pump motor in accordance with motor manufacturer’s instruc- •

tions (motors with greasable bearings only).

Operation and Maintenance Hydraulic System Maintenance
! WARNING !!!
Warning: Lockout/tagout power before performing any adjustment, inspection, lubrication, maintenance or repair
procedures. Disconnect batteries, shut off fuel supply and lockout/tagout engine controls if crusher is powered by a diesel
engine.
Table 10: Hydraulic System Settings and Pressures
Figure
Component 38 44 52 57 68
Reference
Pressure Adjustment Valve 2000 2200 Fig. 9-2 (E)

(Pump Compensator Valve) 2200 3000 2200 Fig. 9-1 (H)
Main Relief Valve 2500 2500 Fig. 9.2 (D)
3400 3400 3400 Fig. 9-1 (D)
Crush Stack N/A N/A Fig. 9-2 (C)
Pressure Reducer Valve 3000 3000 1800 Fig. 9-1 (E)
Hydraulic Cylinder Relief- 2500 2500
Valve 2500 3400 2000
Remote Pump Compensator 1100 1100 Fig. 9-2 (B)
Valve 1500 1500 1500
Cylinder Relief Valve 2500 2500 Fig. 9-2 (H)
2500 3400 2100 Fig. 9-1 (G)

(View Reversed For Clarity)
E
F
F
H
Figure 9–87. Hydraulic Valve Locations (Models 52/57/68)
A. Hydraulic Unit B. System Pressure Max Valve C. Delta Max Valve. D. Main Relief Valve E.Pressure Reducer Valve
F. Counterbalance Valve G. Relief Valve (Lock Cylinder) (DO NOT ADJUST) H. Compensator (Crush/Clear)
Valve (Pump)

E A
Front Right End
Left End
Figure 9–88. Hydraulic Valve Locations (Models 38/44)
A. Hydraulic Unit B. Remote Compensator C. Pressure Reducer Valve (Crush/ D. Main Relief Valve E. Pressure Adjustment Valve
F. Flow Control Valve Valve Clear) (Pressure Compensator)
(Power Rotation) G. Counterbalance Valve H. Relief Valve (Lock Cylinder)

HYDRAULIC SYSTEM MAINTENANCE DEPRESSURIZING THE HYDRAULIC

SAFETY PRECAUTIONS SYSTEM
! WARNING !!! ! WARNING !!!

Failure to observe the following precautions may Pressures of up to 4,000 PSI may be present in
result in serious personal injury or death! the hydraulic system, even when the hydraulic
pump is off. Never attempt to loosen fittings or
• Before beginning any service work, read the following
disconnect hoses unless the hydraulic pressure
sections of this chapter to become familiar with hydraulic
gauge indicates zero (0) PSI and all trapped
system features, adjustments and maintenance items.
pressure has been relieved in the power rotator
• Read the hydraulic system operating instructions in circuit. Serious personal injury or death can
Chapter 8 to become familiar with hydraulic system result if hydraulic oil penetrates the skin.
operating procedures.
• Always lockout/tagout power to the hydraulic control drive, and to all feed and discharge equipment. (Refer to
console before performing any inspections, adjustments, Chapter 1 for complete lockout/tagout procedures.)
maintenance or repairs. Be sure that the hydraulic pump is
2. Be sure the power unit main disconnect switch is ON.
off, and that the pressure gauge indicates zero (0) PSI.
Power must remain connected to the hydraulic control
• Pressures of up to 4,000 PSI may remain trapped in the console during step 3.
power rotator circuit even when the hydraulic pump is off,
3. Depress the STOP button on the hydraulic control con-
and the pressure gauge indicates zero (0) PSI. Always
sole. Move the function selector switch through all three
relieve pressure before disconnecting the power rotator
positions several times. Refer to Figure 9-1.
hoses, or servicing any hydraulic components in the power
rotator circuit. For instructions, refer to the Depressurizing
the Power Rotator Circuit procedure in Chapter 10.
• Allow only trained personnel to perform hydraulic system
maintenance. Any repairs must be made only by certified
hydraulic specialists.
• Be careful when draining hydraulic oil. Hot hydraulic oil
can cause burns. Wear appropriate hand protection and
protective clothing when servicing the hydraulic system.
Avoid unnecessary contact with hydraulic oil.
A
• Dispose of used hydraulic oils in accordance with federal
regulations, and any state and local regulations that apply.
The proper disposal of oils and other toxic materials is the
user’s responsibility.
• Cleaning solvents must be used only in accordance with
manufacturer’s instructions. Always wear appropriate
protective equipment and clothing when using cleaning
solvents and other chemicals.
B
• Never disable the hydraulic system electrical interlocks.
The interlocks prevent the crusher drive motor from Figure 9–89. Control Panel
starting if the hydraulic control console is not energized or A. Function Selector Switch B. Stop Switch
if relief circuit pressure is below acceptable minimum
limits.
• Refer to Chapter 1 for additional safety precautions and
warnings which apply to pressurized systems and related
machinery.

4. Check the hydraulic pressure gauge. The gauge must •Repeat the pressure relief sequence on the second
indicate zero (0) PSI. Refer to Figure 9-2. Repeat step 3 counterbalance valve located on the opposite side of the
if any pressure is indicated on the gauge. valve body.
Figure 9–90. Hydraulic Pressure Gauge

5. Lockout/tagout power to the hydraulic control console.
(Refer to Chapter 1 for complete lockout/tagout proce-
dures).
B
! WARNING !!!
High pressure may remain trapped in the power
rotator circuit even when the hydraulic pressure
gauge indicates zero (0) PSI. Always relieve
pressure as described in the following steps
before disconnecting the power rotator hoses.
Be certain that pressure is completely relieved
before making repairs to the power rotators or to
any other components in the circuit.
Figure 9–91. Counterbalance Valve
6. To relieve trapped pressure in the power rotator circuit,
A. Counterbalance Valve B. Counterbalance Valve (38/44)
perform following steps: (52/57/68)
•.Be sure that power to the hydraulic control console •After relieving pressure, reset the pressure adjustment
remains locked-out. screws to their original settings (turn the adjustment screw
•Locate the counterbalance valve shown in Figure 9-5. counterclockwise the same number of turns as the
Turn the valve pressure adjustment screw clockwise about clockwise adjustment in the previous step).
3 turns. Listen for a “hissing” sound. This indicates that
trapped pressure is being relieved.

HYDRAULIC POWER UNIT

MAINTENANCE PROCEDURES
! WARNING !!!
Lockout/tagout power to the hydraulic control
console before servicing the power unit or
loosening any hydraulic fittings. Be sure that the Full
pressure gauge indicates zero (0) PSI.
! WARNING !!!
Pressures of up to 4000 PSI may remain trapped
in the power rotator circuit even when the
hydraulic pump is off and the pressure gauge Add
indicates zero (0) PSI. Always relieve pressure Oil
before disconnecting the power rotator hoses or
servicing any hydraulic components in the
power rotator circuit. For instructions, refer to
the Depressurizing the Power Rotator Circuit
procedure in Chapter 10.
Hydraulic Oil Level - Check
Table 11: Power Unit Hydraulic Oil

Specifications
Temperature Above 40oF Below 40oF
Range o
(4 C) (4oC)
Viscosity Grade ISO 68 ISO 32 Figure 9–92. Sight Gauge, Hydraulic Reservoir
Standard Type Mobil DTE 16M Mobel DTE 13M 1. Stop the crusher drive motor or diesel engine.
2. Stop the hydraulic pump by depressing the STOP button
Synthetic Type Mobil SHC 526 Mobil SHC 524
on the hydraulic control console. Verify that the hydraulic
Specification ISO 68, HVI AW ISO 38, HVI AW pressure gauge indicates zero (0) PSI.
Low Pour Point Low Pour Point
3. Check the hydraulic reservoir sight gauge. The oil level
Note: Oil capacity for models 38 and 44 is approximately 30 should be up to the black line at the top of the gauge. Refer to
gallons (113 L). Oil capacity for models 52, 57 and 68 is Figure 9-6.
approximately 60 gallons (227 L). Always check oil level with
power unit OFF. Always use new oil poured from a clean con- 4. If the oil level is low, remove the filler cap and add oil as
tainer. required. DO NOT overfill! Refer to Table 3 for oil
specifications.

Hydraulic Oil Filter Indicators - Check

Repeat the following steps for each filter indicator. Refer to
Figure 9-7, 9-8 and 9-9.
1. Be sure that the hydraulic pump is ON.
2. Observe the hydraulic filter indicator. B
•If the filter indicator is GREEN, the filter element is clean

and does not need replacement.
•If the filter indicator is RED, the filter element is dirty
and should be replaced immediately. Refer to the next
paragraph of this section for filter element replacement
procedures.
NOTE: The Pressure Side Filter Indicator on Models A
52/57/68 uses an arrow type filter indicator (Fig 9-8).
Change elements when the arrow is in the Change
Element or Bypass zone.
Figure 9–94. Hydraulic Filter Indicator (Pressure)
A – Filter Assembly (Pressure Side) Models 52/57/68

B – Filter Indicators
Figure 9–93. Hydraulic Filter Indicator (Pressure)
A – Filter Assembly (Pressure Side) Models 38/44

B – Filter Indicators Figure 9–95. Hydraulic Filter Indicator (Suction)
A – Filter Assembly (Pressure Side) Models 52/57/68

B – Filter Indicators

Hydraulic Oil Filter Element - Replace 4. Wipe the inside of the bowl with a clean, lint-free rag.
Inspect the O-ring(s). Replace if worn, deformed, or
Element replacement procedures are the same for both
damaged.
hydraulic oil filters. Repeat the following steps for each filter.
Refer to Figures 9-10, 9-11 and 9-12.
1. Lockout/tagout power to the crusher drive and to the
IMPORTANT:
hydraulic control console (Refer to Chapter 1 for complete To prevent possible damage to the hydraulic system,
lockout/tagout procedures). Be sure the hydraulic pressure use only a 10 micron filter element.
gauge indicates zero (0) PSI. Clean all dust and debris in the 5. Moisten the sealing surface of the new filter element with
area you will be working to prevent contamination. a small amount of hydraulic oil. Then, carefully install the
filter element into the post of the filter head.
! WARNING !!! 6. Install the O-ring(s) and bowl. Tighten to 42 to 50 ft-lbs
(56.9 - 67.7 nm).
Hot hydraulic oil can cause burns! If necessary,
allow oil to cool to a safe temperature before NOTE: On models 38/44 tighten the pressure side
replacing the filter element. Wear appropriate filter bowl to 25 to 30 ft/lbs (33.8 to 40.7 nm).
eye and hand protection. 7. Connect power to the hydraulic control console. Press the
START button, and run the hydraulic pump. Check to be sure
there are no oil leaks. Check that both filter indicators show
full GREEN or the needle is in the CLEAN zone.
Figure 9–96. Hydraulic Oil Filters (Models 38/44)

A. Filter Assembly (Pressure) B. Filter Assembly (Suction)
NOTE:
Figure 9–97. Hydraulic Oil Filters (Models 52/57/68)
The pressure side filter bowl uses one O-ring. The
suction side filter bowl uses two O-rings. A. Filter Assembly (Pressure) B. Filter Assembly (Suction)
2. Place a suitable container under the filter assembly to

catch any spilled hydraulic oil. Carefully rotate the bowl
counter-clockwise and remove it from the filter head. Remove
the O-ring(s) if they do not come off with the bowl.
3. Pull the old filter element straight down to remove it from
the filter head. Discard the old filter element.

A
A
B
F
D
D
E
E
B
G
MODELS 38 and 44 MODELS 52, 57 and 68 ALL MODELS
FILTER ASSEMBLY-PRESSURE SIDE FILTER ASSEMBLY-SUCTION SIDE
Figure 9–98. Exploded View, Hydraulic Oil Filters

A – Filter Indicator C – Filter Element E – Filter Housing G – Plug
B – Filter Head D – O-Ring F – Filter Cover

Filler Cap Assembly - Inspect/Replace

B
hydraulic control console (Refer to Chapter 1 for complete
C
A lockout/tagout procedures). Be sure the hydraulic pressure
gauge indicates zero (0) PSI. Clean the area of any dust or
D
debris.
E 2. Turn the filler cap counterclockwise and remove it from

the flange.
3. Check that the breather holes on the underside of the filler
cap are not blocked by dirt or dust. Replace the filler cap if
clogged or damaged.
F
4. Inspect the filler cap gasket. Replace the gasket if worn,
damaged or missing.
5. Inspect the basket. Remove any sludge or dirt from the
basket openings. Replace the basket if it is cracked or
G
damaged.
6. If necessary, remove screws, flange, basket and both
flange gaskets. Inspect the flange gaskets and replace if worn,
cracked or deformed.
7. After reinstalling or replacing parts, insert the filler cap
into the flange and turn it clockwise until it stops.
Figure 9–99. Hydraulic Filler Cap Assembly

A – Cap Gasket E – Flange
B – Cap F – Flange Gasket
C – Screw G – Basket
D – Chain

B
C
A
D
E
F
Approximate Oil Capcity:

Models 38 and 44 — 30 Gallons (113L) G
Models 52, 57 and 68 — 60 Gallons (227L)
Figure 9–100. Hydraulic Reservoir Maintenance

A – Pump Suction Line C – Gasket E – Nylon Washer G – Magnetic Drain Plug
B – Suction Strainer D – Access Cover F – Bolt
Hydraulic Reservoir - Drain/Clean/Refill 4. Remove bolt, nylon washer and access cover on BOTH
SIDES of the reservoir.
Refer to Figure 9-14 during the following steps. Refer to
other figures as indicated. 5. Inspect the inside of the reservoir for dirt, sludge or other
contaminants. If contaminants are present, determine the
source and make necessary repairs as required.
lockout/tagout procedures). Be sure the hydraulic pressure 6. Wipe all interior surfaces of the reservoir with clean lint-
gauge indicates zero (0) PSI. free rags. Also wipe the interior surface of each access cover.
7. Rotate the suction strainer counter-clockwise and remove
! WARNING !!! it from the pump suction line. Used suction strainers must be
discarded. Do not attempt to clean and reuse an old strainer.
Hot oil can cause burns! Stay clear of hot oil
8. Carefully install a new suction strainer into the pump
during draining procedures. If necessary, allow
suction line. Be careful not to cross thread or overtighten the
oil to cool to a safe temperature before draining.
strainer.
Wear appropriate eye and hand protection
during draining procedures.
2. Slowly loosen the magnetic drain plug and allow the old
oil to drain into a suitable container. Use more than one
container if necessary to hold all the oil.
3. After draining is done, completely remove the magnetic
drain plug and check it for metal particles. An excessive
amount of metal particles on the plug may indicate worn or
defective hydraulic system components. Remove any
particles with a clean lint-free rag. Then re-install the plug.

9. Inspect the gasket around each access cover. Replace the Oil Cooler - Clean/Inspect
gasket if worn or damaged.
10. Secure both access covers with nylon washers and bolts.
NOTE: Hydraulic Oil Cooler for models 52/57/68 is
To prevent leaks, verify that both covers are tight against the
shown in Figure 14. 38/44 model is similar and
reservoir.
servicing is identical.
11. Remove the filler cap. Slowly fill the hydraulic reservoir
with new oil of the proper specifications as shown in Table 3.
Continue filling until the oil level is up to the black line at the
lockout/tagout procedures). Be sure the hydraulic pressure
top of the reservoir sight gauge. Refer to Figure 9-6.
gauge indicates zero (0) PSI.
12. During filling, check the access covers on BOTH SIDES
of the reservoir to be sure that there are no oil leaks.
13. Change both hydraulic filter elements. For instructions,
refer to the filter element replacement procedure earlier in
this chapter.
14. With the crusher OFF, operate all hydraulic functions at
A
least five times to verify proper hydraulic system operation.
Refer to Chapter 8 for complete hydraulic system operating
instructions. Check again for any oil leaks.
15. Disconnect power to the hydraulic control console. Be
sure that the hydraulic pressure gauge indicates zero (0) PSI.
16. Recheck the hydraulic reservoir oil level. If necessary, add
additional oil until the oil level is up to the BLACK line at the
B
top of the sight gauge. Refer to Figure 9-6.
Hydraulic Pump Motor - Inspect/Lubricate
! WARNING !!!
Never attempt to lubricate, clean or repair the
hydraulic pump motor while it is in operation. Figure 9–101. Hydraulic Oil Cooler
Always lockout/tagout power to the hydraulic
control console before starting any service A – Oil Cooler B – Screen
work. 2. Remove the screen from the oil cooler. Clean the screen
• Lockout/tagout power to the hydraulic control console using a suitable brush. Remove any built up dirt or dust.
before inspecting, lubricating, cleaning or repairing the 3. Inspect the oil cooler for leaks or damage. Verify that the
hydraulic pump motor. (Refer to Chapter 1 for complete cooler fins are not bent or clogged. Remove any built up dirt
lockout/tagout procedures). or dust.
• Keep motor ventilation openings free of dust and dirt. 4. Inspect the hydraulic hoses and connections for leakage.
Remove any accumulated material from around the motor Tighten or replace hoses as needed.
housing and from between the cooling fins. Be sure motor
fan openings are clear
• Motors with grease fittings only: Lubricate the motor ! WARNING !!!
regularly. Refer to the motor manufacturer’s instructions Pressurized hydraulic oil can penetrate the skin.
for lubrication intervals and grease specifications. Be sure that the hydraulic pressure gauge
• Be aware of any unusual noises or changes in operation indicates zero (0) PSI before disconnecting the
that could indicate lack of lubrication, worn bearings or hydraulic cooler oil lines or making any repairs
electrical problems. Determine the cause and take to the cooler.
immediate corrective action.

Solenoid Coil - Replace Solenoid Coil - Replace

Type “A” Type “B”
Replace each type “A” solenoid coil as described in the Replace each type “B” solenoid coil as described in the
following steps. Refer to Figure 9-16. following steps. Refer to Figure 9-17.
! WARNING !!! ! WARNING !!!

Never attempt to replace solenoid coils while the Never attempt to replace solenoid coils while the
hydraulic control console is energized. Always hydraulic control console is energized. Always
lockout/tagout power to the hydraulic control lockout/tagout power to the hydraulic control
console before starting any service work. console before starting any service work.
Removal Removal
1. Lockout/tagout power to the crusher drive and to the 1. Lockout/tagout power to the crusher drive and to the
hydraulic control console (Refer to Chapter 1 for complete hydraulic control console (Refer to Chapter 1 for complete
lockout/tagout procedures). Be sure that the hydraulic lockout/tagout procedures). Be sure that the hydraulic
pressure gauge indicates zero (0) PSI. pressure gauge indicates zero (0) PSI.
2. Remove screws, nameplate, cover and cover gasket. 2. Disconnect solenoid coil wires inside the hydraulic
control console (not shown). Note wire locations for later use.
3. Disconnect electrical leads inside junction box. Tag all
leads for identification purposes. 3. Remove nut at end of solenoid coil.
4. Remove the knurled nut and large O-ring. 4. Grasp the solenoid coil and gently pull it away from the
valve body. Be careful not to damage the coil wires.
5. Gently pull the coil away from the valve body. Be careful
not to damage the coil wires. Remove the coil gasket. 5. Test the coil with an ohmmeter. The coil is defective if an
open condition is indicated.
6. Test the coil with an ohmmeter. The coil is defective if an
open condition is indicated.
Installation
Installation 1. Be sure that power remains locked-out.
1. Be sure that power remains locked-out. 2. Slide the new solenoid coil onto the actuator until it is
fully installed.
2. Install the coil gasket over the actuator. Note that the small
round hole of the gasket must line up with the locator pin of 3. Reinstall the nut at the end of the solenoid coil.
the valve body.
4. Reconnect solenoid coil wires inside the hydraulic control
3. Place the solenoid coil on the end of the actuator. console (not shown). If necessary, refer to the schematic
Carefully feed the electrical leads through the coil gasket and diagram in Appendix D.
into the wiring hole of the valve body.
5. With the crusher OFF, operate all hydraulic functions to
4. Slide the actuator towards the valve body while gently verify proper operation. Refer to Chapter 8 for complete
pulling the electrical leads from inside the junction box. Be hydraulic system operating instructions.
sure that the electrical leads are not pinched.
5. Reinstall the large O-ring and knurled nut. Using a hand
wrench, carefully tighten the knurled nut until snug.
6. Reconnect electrical leads as tagged. If necessary, refer to
the schematic diagram in Appendix D.
7. Reinstall cover gasket, cover, nameplate and screws.
8. With the crusher OFF, operate all hydraulic functions to
verify proper operation. Refer to Chapter 8 for complete
hydraulic system operating instructions.

C
A – Screw
B – Nameplate
C – Cover
D D – Cover Gasket
E – Junction Box
F – Valve Body
G – Actuator
E H – Coil Gasket
I – Coil
J – O-Ring
K – Nut
F
G
I
J
K
Figure 9–102. Solenoid Coil Replacement, Type “A”
B
A – Valve Body
B – Actuator
C – Solenoid Coil C
D – Nut
Figure 9–103. Solenoid Coil Replacement, Type “B”

RELIEF CYLINDER MAINTENANCE 1. Lockout/tagout power to the crusher drive and to the
! WARNING !!! gauge indicates zero (0) PSI.
Never attempt to inspect, lubricate, clean or 2. Check for dirt buildup under the cylinder clevis. Remove
repair the relief cylinders while the crusher is in any material from this area. Failure to clean material from this
operation. Always lockout/tagout power to the area can cause damage to couplings, base brackets and the
hydraulic control console before servicing the cylinder.
relief cylinders. 3. Check for dirt buildup under the cylinder coupling.
Remove any material from this area.
Relief Cylinder - Clean/Inspect
4. Repeat steps 2 and 3 for each relief cylinder.
Remove Dirt Buildup.
MODEL 38 MODELS 44, 52, 57

AND 68
Figure 9–104. Relief Cylinder Cleaning

Relief Cylinder - Lubricate 2. Rotate the flange of the cylinder coupling so that the
grease fitting faces OUT, as shown.
3. Using a low-volume hand grease gun, apply several shots
of grease until a small amount of purged grease is visible.
lockout/tagout procedures). Be sure the hydraulic pressure 4. Repeat steps 2 and 3 for each relief cylinder.
Use NGLI #2 grease.
MODEL 38
MODELS 44, 52, 57

AND 68
Figure 9–105. Cylinder Coupling Lubrication

Relief Valve - Replace 4. Using an open end wrench, tighten the valve an additional
amount until it is snug. Do not overtighten.
! WARNING !!!
IMPORTANT:
Be sure pressure gauge indicates zero (0) PSI Do not attempt to clean, re-adjust or repair a defective
before removing relief valve from manifold. relief valve. Improper hydraulic system operation may
Refer to Figures 9–20 and 9–21. occur.
Each relief cylinder has a relief valve. Use the following
procedure when relief valve replacement is necessary:
A
gauge indicates zero (0) PSI. Clean the area of dust and debris
to prevent dirt contamination.
2. Using an open end wrench, carefully loosen the relief
valve and remove it from the manifold.
NOTE: New relief valves mounted on the relief
cylinders are pre-set to:
Model 38/44/52 : 2500 PSI (175 bar).
Model 57: 3400 PSI (234 bar)
Model 68: 2100 PSI (144 bar)
3. Place the new relief valve into the threaded opening of the
manifold. Hand tighten the valve, making sure that it is not
cross-threaded. Figure 9–106. Model 38 Relief Valve
Figure 9–107. Models 44–68 Relief Valve
A. Relief Valve B. Grease Fitting

POWER ROTATOR MAINTENANCE

A
! WARNING !!!
Never attempt to adjust, lubricate, clean or repair B
the power rotator assembly while it is in
operation. Stay clear all moving parts while
observing power rotator operation. Always
lockout/tagout power to the hydraulic control
console before servicing the power rotator.
NOTE:
Clean This
Models 38 and 44 Gyraspheres are equipped with a Area
s i n g l e p o w e r r o t a t o r, M o d e l s 5 2 , 5 7 a n d 6 8
Gyraspheres are equipped with two power rotators.
Maintenance procedures are the same for all units.
Cleaning and Inspection Figure 9–109. Power Rotator Gears

A. Ring Gear B. Pinion Gear
lockout/tagout procedures). Be sure the hydraulic pressure 3. If the ring gear moves erratically when making
gauge indicates zero (0) PSI. adjustments, check the area around the motor shaft and pinion
gear for built-up dirt. Clean as necessary. If the motor pinion
gear is not making proper contact with the ring gear, adjust
B
the gear backlash using the procedure outlined in the
following paragraph.
4. Reinstall the power rotator cover after servicing is
completed.
Figure 9–108. Gear Cover

A. Gear Cover B. Capscrew (4 used)
2. Remove the power rotator gear cover. Inspect the power

rotator ring and pinion gears for obvious wear or looseness.
Remove any built-up dirt or stone. Refer to Figures 9-22 and
9-23.

Gear Backlash Adjustment 4. Tighten the adjusting bolts to decrease backlash, or loosen
them to increase backlash.
lockout/tagout procedures). Be sure the hydraulic pressure ! CAUTION !!!
If backlash must be increased, it may be
necessary to operate the OPEN and CLOSE
functions to move the motor against the ends of
the adjusting bolts. During operation, stay clear
of gear teeth and all other moving parts to
prevent serious personal injury.
5. Measure backlash after making adjustments. Repeat
step 4 until backlash is within specification.
Insert Feeler
6. Tighten locking nuts and mounting bolts.
Gauge Here. 7. Reinstall the power rotator gear cover.
Figure 9–110. Checking Gear Backlash

2. Remove the power rotator gear cover. Insert a feeler gauge
between the teeth of the ring and pinion gears where the gears
mesh. Backlash between the gears should be 0.020” - 0.030”
(0.50 - 0.75 mm). Refer to Figure 9-24.
A A
B
Figure 9–111. Motor Backlash Adjustment Bolts

A.Adjusting Bolt (2 used) B.Locking Nut (2 used)
C.Mounting Bolt (4 used)
3. If backlash is NOT correct, loosen the locking nuts and

mounting bolts. Refer to Figure 9-25.

Gearbox Oil Level - Check
IMPORTANT:
Due to the gearbox mounting position, the oil level
gauge on the gearbox housing WILL NOT provide
accurate oil level readings. Check the oil level only as
A
described in the following steps:
1. Lockout/tagout power to the crusher drive and to the B
Figure 9–114. Breather Assembly

A.Breather Assembly B. Nipple
4. Remove the breather assembly from the nipple. Refer to

Figure 9-28.
B 5. Slowly add oil to the nipple until oil begins to flow from
the oil level tube. Refer to Table 4 for oil specifications.
Figure 9–112. Gear Cover
6. Reinstall the breather assembly and the oil level cap.
A. Gear Cover B. Capscrew (4 used)
7. Reinstall the power rotator gear cover.
2. Remove the power rotator gear cover.
Refer to Figure 9-26.
Figure 9–113. Gearbox Oil Level Cap

A.Oil Level Cap
3. Remove the oil level cap from the oil level tube. Refer to
Figure 9-27. Note that the cap is located under the pinion
gear.

Gearbox Oil - Drain/Refill

Table 12: Oil Specifications - Power Rotator
1. Lockout/tagout power to the crusher drive and to the Gearbox
lockout/tagout procedures). Be sure the hydraulic pressure AMBIENT
gauge indicates zero (0) PSI. TEMPERATURE
2. Place a suitable container under the gearbox drain.
3. Remove the drain plug. Refer to Figure 9-29. SPECIFICATION
Below Above
4. Allow all oil to drain from the gearbox. 40°F 40°F (4.5
(4.5°C) °C)
5. Reinstall the drain plug.
6. Fill the gearbox to the proper level with the correct gear Viscosity ISO Grade 100 150
oil. Refer to Table 4 for gear oil specifications. Refer to the oil Viscosity AGMA Grade 3 EP 4 EP
level check procedure earlier in this chapter for gearbox #250.04
filling instructions.
Viscosity SUS @ 100°F 469 to 575 709 to 871
NOTE: Viscosity SUS @ 210°F 61 to 67 74 to 82
Gearbox oil capacity is approximately 2.2 gallons (8.33 Viscosity Index 95 Min. 95 Min.
L).
Timken OK Load (Lbs.) 60 Min. 60 Min.
Extreme Pressure Agent Yes Yes

(EP)
Copper Strip Corrosion Pass Pass

Test
Oil must not be corrosive to metals generally used in

bearings, gears, shaftings, pumps, and housings.
Oil must have the least possible effect on rubber
seals, synthetic seals, packings, and hoses.
Figure 9–115. Gearbox Drain Plug Location

A. Drain Plug

ANTI-SPIN AIR BLEED PROCEDURE 3. Install and tighten a #10 JIC cap over the M1 hose adapter
fitting.
Air bleeding of the Anti-Spin Circuit is necessary only if the
circuit has been opened or major repairs have been made. If 4. Place the hose end in a bucket. Turn on the main
required, bleed the anti-spin circuit as described in the disconnect switch on the front of the hydraulic power unit,
following steps: and press the START button. Run the pump until the oil
flowing from the hose is free of air bubbles.
IMPORTANT: 5. Press the STOP button. Lockout/tagout power to the

hydraulic control console.
Air in the Anti-Spin Circuit will result in improper
operation of the anti-spin system and may result in 6. Remove the cap from the adapter fitting. Reconnect the
p e r m a n e n t d a m a g e t o t h e a n t i - s p in hy d ra u l i c M1 motor hose. Refer to Figure 9-30.
components.
7. Reconnect power to the hydraulic control console.
Operate each hydraulic function at least five times to bleed
any trapped air from the system. Verify that each function
operates properly.
8. Depress the STOP button. Cycle the function selector
switch through all three positions and verify that hydraulic
pressure gauge indicates zero (0) PSI.
9. Re-check the oil level in the hydraulic reservoir sight
gauge. If the oil level has dropped, add additional oil until the
oil level is up to the BLACK line at the top of the gauge. Refer
to Table 3 for hydraulic oil specification.
Figure 9–116. Anti-Spin Valve
A.Optional Sensor (Trac 10 B.Pressure Test Port

equipped models) D. Anti-Spin Valve Body
C. M1 Hose Port Adapter Fitting
1. Lockout/Tagout power to the crusher drive and to the

gauge indicates zero (0) psi.
2. Locate the anti-spin valve body on the crusher frame to
the left of the countershaft. Refer to Figure 9-30. Disconnect
the M1 motor hose (anti-spin) from the adapter fitting on the
valve body.

BUTTRESS THREAD LUBRICATION Table 13: Moly-Based EP-2 Grease

Periodic lubrication of the buttress threads will help ensure
that the support bowl turns freely when unlocked. Lubricate Worked Penetration 265/295
the buttress threads as described in the following steps:
1. Lockout/tagout power to the crusher drive (Refer to
Chapter 1 for complete lockout/tagout procedures). Rust Prevention (ASTM D-1743) Pass
2. Lockout/tagout power to the hydraulic control console Corrosion Prevention Pass

(Refer to Chapter 1 for complete lockout/tagout procedures). (ASTM D-1261)
3. Apply several shots of Moly-based EP-2 grease to each of Oxidation Stability (ASTM D-942)
the four lubrication fittings located on the upper frame. Refer
to Figure 9-31. Refer to Table 5 for grease specifications. Oxygen Absorption
(PSI) <3
After 100 Hours <4
200 Hours <5
300 Hours
Oil Viscosity, SUS @ 100 °F

Timken Load 65
Four Ball Weld Point 800
Wear Scar 0.51 mm
B
Type of Soap Aluminum
Complex
B Operating Temperature 0 to 450°F

A
Figure 9–117. Buttress Thread Lubrication

A. Lubrication Fitting B. Lock Cylinder

Activate the hydraulic system and rotate the support bowl
assembly back-and-forth several times. Refer to Chapter 8 for
hydraulic system operating instructions.

NOTES

Chapter 10
Hydraulic System Troubleshooting
CONTENTS
Page
HYDRAULIC SYSTEM TROUBLESHOOTING SAFETY . . . . . . . . . . . . . . . . . . . . . . 10-2
DEPRESSURIZING THE POWER ROTATOR CIRCUIT. . . . . . . . . . . . . . . . . . . . . . 10-3
DISCONNECTING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
PRELIMINARY CHECKS & INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
HYDRAULIC SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 10-6
ELECTRICAL COMPONENT AMPERAGE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . 10-7

Hydraulic System Troubleshooting Operation and Maintenance
HYDRAULIC SYSTEM pressure has been relieved. Always assume that the line
TROUBLESHOOTING SAFETY has pressure.
• Use a piece of cardboard to check for hydraulic oil leaks,
not your hand. Escaping fluid under pressure can penetrate
! WARNING !!! the skin, resulting in serious personal injury.
Lockout/tagout power to the hydraulic control • Avoid unnecessary contact with hydraulic oil. Wear
console before performing any inspections, appropriate hand protection and protective clothing when
adjustments, maintenance, or repairs. Never troubleshooting the hydraulic system.
attempt to service the hydraulic system while it
is operating. Refer to Chapter 1 for complete • Clean-up any spilled hydraulic fluid. Hydraulic fluid is
lockout/tagout procedures. extremely slippery, and can be especially dangerous if
• Refer to Chapter 1 for additional safety precautions and
! WARNING !!! warnings which apply to pressurized systems and related
Failure to observe the following precautions may machinery.
result in serious personal injury or death!
• Always lockout/tagout power to the hydraulic control
console before performing any inspections, adjustments,
maintenance or repairs. Be sure that the hydraulic pump is
off, and that the pressure gauge indicates zero (0) PSI.
(Refer to Chapter 1 for complete lockout/tagout
procedures).
• Pressures of up to 4000 PSI may remain trapped in the
power rotator circuit even when the hydraulic pump is off
and the pressure gauge indicates zero (0) PSI. Relieve
pressure as described later in this chapter before
disconnecting the power rotator hoses or servicing any
hydraulic components in the power rotator circuit.
• Allow only qualified hydraulic service technicians to
perform hydraulic system troubleshooting. All persons
working on the hydraulic system must have appropriate
training and certification.
• Allow only licensed electricians to troubleshoot hydraulic
system electrical components and wiring.
• Use common sense when observing hydraulic system
operation. Be aware of potential hazards at all times. Stay
clear of all moving or rotating parts.
• Be sure to wear appropriate safety devices, such as hard
hats, safety glasses, face shield and ear protection.
• Be sure that the pressure gauge indicates zero (0) PSI
before beginning any maintenance or repairs to the
hydraulic system.
• Never attempt to loosen a hydraulic fitting while the
hydraulic system is pressurized. You could be injured or
killed by a stream of high pressure oil.
• Never have your face near, or stand directly in front of a
hydraulic line when cracking a fitting, even after system

Operation and Maintenance Hydraulic System Troubleshooting
DEPRESSURIZING THE POWER 4. Locate counterbalance valve “A” shown in Figure 10-2
ROTATOR CIRCUIT and 10-3. See Figure 10-4 for valve details.
! WARNING !!!
Pressures of up to 4000 PSI may remain trapped
in the power rotator circuit even when the
hydraulic pump is off and the pressure gauge
indicates zero (0) PSI. Relieve pressure as
d e s c r i b e d i n t h e fo l l ow i n g s t e p s b e fo r e
disconnecting the power rotator hoses or B
servicing any hydraulic components in the A
power rotator circuit.
drive and to all feed and discharge equipment (Refer to
2. Stop the hydraulic pump. Lockout/tagout power to the
hydraulic control console.
3. Check the hydraulic pressure gauge. Verify that the gauge
indicates zero (0) PSI. See Figure 10-1.
Figure 10–119. Counterbalance Valves (Models 38/

44)
A.Counterbalance Valve A B. Counterbalance Valve B
Figure 10–118. Hydraulic Pressure Gauge (Model 52/

57/68 shown)

A
B
Figure 10–120. Counterbalance Valves (Models 52/57/68)

A. Counterbalance Valve “A” B. Counterbalance Valve “B”
5. Loosen the pressure adjustment screw locknut (Fig. 10-4).

6. Turn the pressure adjustment screw CLOCKWISE about
three turns. Listen for a “hissing” sound. This indicates that
pressure is being relieved.
7. After relieving pressure, reset the pressure adjustment
A
screw to its original setting (turn the pressure adjustment
screw COUNTERCLOCKWISE the same number of turns as
in step 6).
8. Re-tighten the pressure adjustment screw locknut (Fig.
10-4).
9. Repeat steps 5 through 8 for counterbalance valve “B”.
Refer to Figures 10-2 and 10-3.
IMPORTANT:
Pressure must be relieved at both counterbalance B
valves to ensure that all pressure in the power rotator
circuit is completely relieved.
10. To verify that pressure has been relieved, check that both
power rotator hoses are relaxed and not stiff. A stiff hose Figure 10–121. Counterbalance Valve Details
indicates that high pressure remains trapped in the circuit.
A.Pressure Adjustment Screw B. Locknut

DISCONNECTING HYDRAULIC HOSES PRELIMINARY CHECKS &

INSPECTIONS
! WARNING !!! Make the following checks and inspections before
performing any hydraulic system troubleshooting
Always stop the hydraulic pump and lockout/ procedures:
tagout power to the hydraulic control console
before disconnecting hydraulic hoses or • Check the hydraulic reservoir oil level. Reservoir is full
loosening hydraulic fittings. Be certain that any when the oil level is up to the black line at the top of the
trapped pressure is completely relieved. Failure gauge. Add oil if low. Refer to Chapter 9 for oil
to observe these precautions may result in the specifications.
release of high pressure hydraulic oil. • Check for visible external leakage on hydraulic system
• Up to 4000 PSI may remain trapped in the power rotator fittings. Lockout/tagout power and be sure all hydraulic
circuit even when the hydraulic pump is off and the pressure is completely relieved before tightening or
pressure gauge indicates zero (0) PSI. Always relieve replacing any fittings.
pressure as described earlier in this chapter before • Check for visible external leakage on valves, cylinders
disconnecting the power rotator hoses. and other hydraulic components. Repair or replace
• Be sure that the hydraulic pressure gauge indicates zero defective components as required to eliminate leaks.
(0) PSI before disconnecting the relief cylinder hoses. Lockout/tagout power and be sure all hydraulic pressure
is completely relieved before making repairs.
• Be sure that the hydraulic pressure gauge indicates zero
(0) PSI before disconnecting the locking cylinder hoses. • Check that the hydraulic power unit is securely mounted
on a flat, level surface.
• Be sure that the hydraulic pressure gauge indicates zero
(0) PSI before disconnecting the anti-spin unit hoses (if • Be sure proper voltage is connected to the hydraulic
equipped). control console. Be sure polarity is not reversed.
• Before disconnecting a hydraulic hose, verify that it is • All power unit electrical components must be correctly
relaxed and not stiff. A stiff hose indicates that pressure wired and in proper working order. If electrical problems
has not been relieved. are suspected, have a licensed electrician inspect and
troubleshoot the system. Refer to Appendix D for the
• As hydraulic hoses are disconnected, catch any oil hydraulic system electrical schematic.
leakage in an appropriate container.
! WARNING !!!
Always assume that the system is pressurized,
even if pressure appears to have been relieved.
Wear appropriate eye protection and other
personal protective equipment when loosening
hydraulic fittings and disconnecting hydraulic
hoses. Serious personal injury or death can
result if hydraulic oil penetrates the skin.

HYDRAULIC SYSTEM As required, also refer to the schematic diagrams in Appendix

TROUBLESHOOTING CHART D during troubleshooting procedures.
Refer to Table 10-1 for the hydraulic system troubleshooting

chart. When indicated in the Corrective Action column, refer
to the hydraulic system maintenance procedures in Chapter 9.
Table: 10-1 Hydraulic System Troubleshooting
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
7. Crusher will not run. (Hydraulic a . I n c o r r e c tl y w ir e d p r e s s u r e Correct switch connections.

low pressure switch PS-1 switch.
open.)
b. Defective electric motor Repair or replace motor.
(hydraulic pump)
c. Clogged hydraulic oil filter. Change filter element.
d. Incorrect relief valve setting or Adjust or replace relief valve.

defective relief valve.
e. Defective hydraulic pump. Repair or replace pump.
8. Support bowl assembly does a. Locking cylinders do not release. Check locking cylinder hydraulic
not move when OPEN/CLOSE hoses for proper connections.
buttons are pushed.
Check for clogged or crimped
hoses.
Check locking cylinder solenoid
valve for proper operation
Check that unlock pressure is
135psi at test gauge port on lock
cylinder stack.
b. Power rotator pinion gear not Adjust power rotator gear backlash.
contacting r ing gear on upper Refer to Chapter 9.
frame.
c . D e fe c t i v e O P E N / C L O S E Re pla ce soleno id or valve as

solenoid valve. needed.
d. Defective hydraulic motor Replace motor.

(power rotator)
e. Corrosion on bowl threads is Apply grease to four buttress

preventing power rotator from thread grease fittings. Reattempt
rotating bowl. rotation with OPEN/CLOSE
Buttons. Severe corrosion may
require the bowl to be manually
rotated and the threads cleaned.
9. EXTRACT HIGH SPEED Defective high-speed solenoid Re pla ce soleno id or valve as

mode does not rotate upper valve. needed.
frame at high speed.

Table: 10-1 Hydraulic System Troubleshooting
SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION
10. Support bowl assembly rotates Locking cylinders not pressurized. Check locking cylinder hydraulic
while crushing. hoses for proper connections.
hoses.
Check locking cylinder solenoid
valve for proper operation.
11. Upper frame moves up and Relief cylinders not pressurized. Check hydraulic relief hoses for
down while crushing. proper connections.
hoses.
Check relief cylinder solenoid valve
for proper operation.
12. Anti-spin does not function. a. Trapped air in anti-spin hydraulic Purge air from the anti-spin
circuit. hydraulic circuit. Refer to the
Telsmith Anti-Spin Unit Installation,
Operation and Troubleshooting
Manual for air bleeding procedure.
b. M e c h a n i c a l o r hy d r a u l i c Refer to the Telsmith Anti-Spin Unit

problems within anti-spin unit. Installation, Operation and
Tr o u b l e s h o o t i n g M a n u a l fo r
complete anti-spin troubleshooting
procedures.

ELECTRICAL COMPONENT
AMPERAGE CHECKS
When troubleshooting hydraulic system problems, the
amperage draw of electrical components in the system can
help isolate problems. Typically, components that are
drawing 25% greater amperage than the nameplate rating can
indicate a problem with the electrical component itself, a
problem in the associated electrical circuit, or a problem with
the controlled mechanical component (valve, pump etc.).
Table 10–2. Typical Electrical Amperage Draws
Model Component Amperage Draws Overamperage Condition
38/44 Hydraulic Pump Motor 5 - 7 amps at 460V

(460V)
38/44 Hydraulic Pump Motor 6 - 9 amps at 380V 16.5 amps or greater

(380V)
52/57/68 Hydraulic Pump Motor 8 - 10 amps at 460V

(460V)
52/57/68 Hydraulic Pump Motor 9 - 12 amps at 460V

(380V)
38/44 Crush/Clear Solenoid Coil 0.42 - 0.50 amps .65 amps or greater
38/44 Power Rotate Solenoid Coil 0.42 - 0.50 amps .65 amps or greater
38/44 Lock Cylinder Solenoid Coil 0.42 - 0.50 amps .65 amps or greater
52/57/68 Crush/Clear Solenoid Coil 0.42 - 0.50 amps .65 amps or greater
52/57/68 Power Rotate Solenoid Coil 0.42 - 0.50 amps .65 amps or greater
52/57/68 Lock Cylinder Solenoid Coil 0.42 - 0.50 amps .65 amps or greater

Chapter 11
V-Belt Drive Adjustment and Maintenance
CONTENTS
Page
V-BELT DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
V-BELT CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
V-BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
V-BELT TENSION - CHECK & ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
MEASURING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
DRIVE MOTOR LUBRICATION & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

V-Belt Drive Adjustment and Maintenance Operation and Maintenance
V-BELT DRIVE COMPONENTS
B
C
D
N
E
F
M
L
K
J
I G
O
P
Q
Figure 11–122. V-Belt Drive (Typical)

A – V-Belt Drive Guard F – Capscrew K – Countershaft P – Washer
B – Bushing Key G – Tapered Bushing L – Motor Sheave Q – Slide Rails
C – Flywheel Sheave H – Capscrew M – Motor Bushing Key R – Tapered Bushing
D – Key Retaining Setscrew I – Lock Washer N – Electric Motor S – V-Belts
E – Lock Washer J – Key Retaining Setscrew O Nut

Operation and Maintenance V-Belt Drive Adjustment and Maintenance
• Periodically wipe V-belts clean with a dry cloth. If

! WARNING necessary, use soap and water or a non-flammable
Use extreme caution if it is necessary to observe cleaning solvent.
the V-belt drive in operation. Stay clear of • Keep V-belts free of oil, grease, and other lubricants that
sheaves, V-belts and other moving parts. may cause slippage or premature wear.
Lockout/tagout power to the crusher drive motor
before performing any V-belt drive inspection, • Never mix old and new V-belts on a drive. This will result
adjustment or maintenance procedures. If the in stretching and premature failure of the new belts.
crusher is powered by a diesel engine, shut-off Always replace all V-belts as a set.
fuel supply and lockout/tagout engine controls. • If V-belts hit against the drive guard, check for excessive
See to Chapter 1 for complete lockout/tagout crusher vibration or loose V-belt tension. Verify that the
procedures. guard is properly installed.
• Always reinstall the drive guard after making tension
V-BELT CARE AND MAINTENANCE adjustments or performing maintenance procedures.
• Check V-belt tension regularly. For the most accurate
measurements, use a spring scale to check tension as SHEAVE INSPECTION
described later in this chapter.
Refer to Figure 11–1 as necessary.
• Replace V-belts that show signs of obvious damage, such
as ruptures or cuts. Replace V-belts that have turned over 1. Lockout/tagout power to the crusher drive. See Chapter
in their grooves. 1 for complete lockout/tagout procedures.
• Replace excessively worn or stretched V-belts. Do not use 2. Remove any accumulated dirt from the sheave faces. A
belt dressing to prevent belts from slipping. build-up of dirt in this area can cause an out-of-balance
condition. See Figure 11–2.
3. Visually inspect the sheaves. Replace any obviously
damaged or wobbling sheaves. See Figure 11–2.
A B
Figure 11–123. Sheave Inspection

A – Remove dirt and debris B – Replace worn or damaged sheaves

4. Check the sheaves for looseness. Tighten sheave 4. Adjust the slide rails so that the V-belts can be installed
capscrews as required. without forcing. Place the belts in the sheave grooves. Be sure
that the slack in all belts is on the same side of the drive.
5. Remove any accumulated dirt from the sheave grooves.
Inspect the grooves for rust, nicks, and burrs. Use a gauge to 5. Place a straight edge or tight cord across the sheave faces.
measure groove wear. See Figure 11–3. Check that the sheaves are precisely aligned and that the
shafts are parallel. See Figures 11–4 and 11–5.
6. Use a straight edge to check for proper sheave alignment.
If V-belts are turning over in their grooves or are worn
excessively on one side, sheave misalignment is probably the
cause.
7. Make certain guards are not rubbing against sheave or
counter shaft.
V-BELT INSTALLATION
SHEAVE GROOVES OK
Refer to Figure 11–1 as necessary.
2. Inspect the sheave grooves. Remove any rust or burrs.
Clean off any oil or grease.
3. Rotate both sheaves by hand and check that they do not SHEAVE GROOVES WORN
wobble. Inspect each sheave for signs of obvious wear or (DISHED OUT)
damage.
Figure 11–124. Sheave Groove Inspection
PROPER ANGULAR PARALLEL

ALIGNMENT MISALIGNMENT MISALIGNMENT
Figure 11–125. Sheave Alignment and Misalignment

6. Using a hand wrench, evenly turn the slide rail bolts (as
required) until the V-belts are taut and fully seated in the IMPORTANT:
grooves. Misalignment of more than one-half of one degree (1/8
7. Recheck the sheave alignment as shown in Figure 11–5. inch in one foot) will greatly reduce V-belt life.
Verify that the sheaves remain precisely aligned. Misalignment will cause the V-belts to wear prematurely
on one side and may also cause them to roll over in the
sheave grooves.
8. Adjust V-belt tension as described in the following
section.
EQUAL UNEQUAL
FLANGE FLANGE
THICKNESS THICKNESS
B C
1 1
2 2
D
Combined thickness of gap (B)
and narrow flange (C) equals
A
dimension (D). Dimension (D)
and wide flange dimension (E)
MUST be equal.
E
3 3 F
4 4
Sheave flanges must be Sheave flanges must be

parallel to string. String parallel to string. Check
must touch at all four at all four points.
points.
Figure 11–126. Checking Sheave Alignment
A – Equal Thickness Flanges C – Narrow Flange E – Wide Flange Dimension

B – Gap D – Combined Dimension F – Wide Flange

V-BELT TENSION - CHECK & ADJUST 4. Used V-belts only: Record the deflection force measured
by the spring scale in step 3. It should be within the minimum
Refer to Figure 11–1 as necessary. and maximum values listed in Column II of Figure 11–6.
Chapter 1 for complete lockout/tagout procedures). Remove IMPORTANT:
the V-belt drive guard if it is not already removed.
To prevent accidental overtightening, use a hand
2. Measure the V-belt span as shown in Figure 11–6.Using a wrench to adjust V-belt tension in the following step. DO
spring scale, apply enough force on one V-belt until it is NOT use an impact wrench.
deflected 1/64 inch for each inch of span length. For example,
the amount of deflection required for a 100 inch span would 5. Adjust V-belt tension if the deflection force is too high or
be 1/64 inch x 100, or 1-9/16 inches. too low. To adjust tension, first loosen the motor mounting
nuts. Then use a hand wrench to evenly turn the slide rail bolts
3. New V-belts only: Record the deflection force measured (as required) until the proper tension is achieved.
by the spring scale in step 3. It should be equal to or close to
the value listed in Column I of Figure 11–6. 6. After adjusting tension, check that the sheaves remain
precisely aligned as shown in Figure 11–5. Then retighten the
motor mounting nuts.
Table 11–1. Deflection Force V-Belts
Force (B)
Deflection (C) =1/64 inch per inch of

I II
Belt Span (A) at Force (B).
Motor Used V-Belt
New V-Belt
Belt Sheave Deflection
Deflection
Type Diameter (lbs min-
(lbs)
(inches) max)
5V 8.5 to 10.9 25 13-19

A 11.8 to 16.0 29 15-22
B
8V 12.5 to 17.0 59 31-45
18.0 to 24.0 70 36-53
C 11.0 to 16.0 26 13-20

C D 13.5 to 15.5 42 22-33
16.0 to 22.0 49 25-37
NOTE: Tighten new V-Belt to the value listed in Column I. After 24

hours of operation, check that tension has dropped to within normal
values in Column II. Readjust tension as required
Figure 11–127. V-Belt Deflection Force


! CAUTION drive and make the following additional checks:
Use extreme caution when observing the V-belt • With the power locked-out, touch a groove on one of the
drive in the following steps. Stay clear of sheaves. If you cannot hold your finger in the groove, the
sheaves and V-belts. Lockout/tagout power drive is running too hot. The heat may be caused by loose
before making any adjustments, inspections or V-belt tension, but could also be the result of an external
repairs. source. Determine the cause before re-starting the crusher.
7. To verify that tension is correct, operate the crusher for a • With the power locked-out, firmly depress one of the V-
few minutes while viewing the V-belt drive from a safe belts midway between the flywheel sheave and the motor
distance. Make the following checks and observations: sheave. As a general rule, the belt deflection at this point
• Listen to the V-belts as the crusher is started. A small should not be greater than the thickness of the adjacent V-
amount of slippage is normal. However, if belt squeal is belts.
audible, tension is probably too loose. 9. Reinstall the V-belt drive guard after verifying that
• Check that there is a slight bow or sag in the slack side of tension is properly adjusted. Be sure that the guard does not
the drive when operating at full load. This is an indication make contact with the drive components or crusher.
of proper tension. See Figure 11–7. 10. When operating with new drive belts a breakin period
• If there is a large bow or sag on the slack side of the drive, may occur. Verify belt tension every day of the first week of
or if belt whipping occurs, tension is too loose. operation to ensure belts have not loosened.
! WARNING
TENSION CORRECT
A Reinstall the V-belt drive guard after completing
t e n s i o n a d j u s t m e n t s o r p e r fo r m i n g a ny
maintenance or repairs. Failure to reinstall the
guard will result in an entanglement hazard.
OK
Serious personal injury or death could occur.
OK
TENSION TOO
C
LOOSE
Figure 11–128. V-Belt Tension (Visual Check)

A – Slight Bow B – Large Bow C – Belt Whip

MEASURING GEAR BACKLASH Table 11–2. Measuring Gear Backlash at Flywheel

Gear backlash should be checked whenever the V-belt drive Rim
is inspected. See figure 11–8.
Backlash
1. Lockout/tagout power to the crusher drive (Refer to Flywheel Measured at
Model
Chapter 1 for complete lockout/tagout procedures). Sheave O.D. Flywheel Rim
(Dimension X)
2. Remove the V-belt drive guard if it is not already
removed. 38 23.6 inch 0.0625 to 0.0937
inch
3. Gently rock the flywheel sheave back-and-forth. Using a
dial indicator, measure backlash at the rim. 44 24.4 inch 0.0625 to 0.0937
inch
4. Rotate the sheave one-quarter turn (90°). Measure
52 33.6 inch 0.0625 to 0.0937
backlash again. inch
5. Repeat steps 3 and 4 until a total of nine measurements 57 33.6 inch 0.0625 to 0.0937
have been made, and the sheave has been rotated two full inch
turns. The average of all measurements should not exceed the
range shown in Table 11-2. If backlash is not within 68 40.0 inch 0.0625 to 0.0937
inch
acceptable limits, see Chapter 9 of your SBS Repair &
Overhaul manual for backlash adjustment procedure. Note: Backlash measurements shown above are typical.
Actual measurements may vary depending on flywheel
6. Reinstall the V-belt drive guard after making sheave O.D., fabrication variables and other factors.
measurements. Be sure that the guard does not make contact
with any drive components.
DRIVE MOTOR LUBRICATION &
MAINTENANCE
• Lockout/tagout power before servicing the crusher’s
electric drive motor (Refer to Chapter 1 for complete
lockout/tagout procedures).
• Keep motor ventilation openings clear of dust and dirt.
Remove any accumulated material from around the motor
housing and from between the cooling fins.
• Lubricate the motor regularly, at the recommended
intervals shown in the motor manufacturer’s manual. Be
sure to use the correct grade of grease as specified for your
operating conditions.
• Be sure that the motor is tightly secured to the slide rails.
Check that the slide rail mounting bolts are securely
fastened to the motor platform or foundation. Tighten any
MEASURE BACKLASH AT FLYWHEEL RIM
loose fasteners. Remove any loose dirt from slide rails.
• Be aware of any unusual noises or changes in operation
that could indicate lack of lubrication, worn bearings or
electrical problems. If present, determine the cause and
Figure 11–129. Measuring Gear Backlash at Flywheel take immediate corrective action.
Rim

Extec SBS Cone Crusher Appendix A - Torque Tables
Models 38-57
Fastener Information SAE J429 Grade 2 SAE J429 Grade 5
Size Thread Threads Major Dia. Tensile Torque Torque Torque Torque
Type Per Inch (in) Stress Dry Lubricated Dry Lubricated
(n) Area (in-lb)/(ft-lb) (in-lb)/(ft-lb) (in-lb)/(ft-lb) (in-lb)/(ft-lb)
(in2)
1/4 UNC 20 0.2500 0.0318 66 49 100 76

UNF 28 0.2500 0.0364 75 56 120 87
5/16 UNC 18 0.3125 0.0524 11 8 17 13

UNF 24 0.3125 0.0581 13 9 19 14
3/8 UNC 16 0.3750 0.0775 20 15 31 23

UNF 24 0.3750 0.0878 23 17 35 26
7/16 UNC 14 0.4375 0.1063 32 24 49 37

UNF 20 0.4375 0.1187 36 27 55 41
1/2 UNC 13 0.5000 0.1419 49 37 75 57

UNF 20 0.5000 0.1600 55 41 85 64
9/16 UNC 12 0.5625 0.1819 70 53 110 82

UNF 18 0.5625 0.2030 78 59 120 91
5/8 UNC 11 0.6250 0.2260 97 73 150 110

UNF 18 0.6250 0.2560 110 83 170 130
3/4 UNC 10 0.7500 0.3345 170 130 270 200

UNF 16 0.7500 0.3730 190 140 300 220
7/8 UNC 9 0.8750 0.4617 170 120 430 320

UNF 14 0.8750 0.5095 180 140 470 360
1 UNC 8 1.0000 0.6057 250 190 640 480

UNF 12 1.0000 0.6630 270 210 710 530
1 1/8 UNC 7 1.1250 0.7633 350 270 800 600

UNF 12 1.1250 0.8557 400 300 890 670
1 1/4 UNC
UNF
7
12
1.2500
1.2500
0.9691
1.0729
500
550
380
420
1,100
1,200
840
930 7F
1 3/8 UNC 6 1.3750 1.1549 660 490 1,500 1,100
UNF 12 1.3750 1.3147 740 560 1,700 1,300
1 1/2 UNC 6 1.5000 1.4053 870 650 2,000 1,500

UNF 12 1.5000 1.5810 980 730 2,200 1,600
ASTM A307 Grade A ASTM A449
1 3/4 UNC 5 1.7500 1.8995 1,400 1,000 2,300 1,700

1 3/4 UN 12 1.7500 2.1873 1,600 1,200 2,600 2,000
2 UNC 4 1/2 2.0000 2.4982 2,100 1,500 3,400 2,600

2 UN 12 2.0000 2.8917 2,400 1,800 4,000 3,000
2 1/4 UNC 4 1/2 2.2500 3.2477 3,000 2,300 5,000 3,800

2 1/2 UNC 4 2.5000 3.9988 4,100 3,100 6,900 5,200
2 3/4 UNC 4 2.7500 4.9340 5,600 4,200 9,400 7,000
3 UNC 4 3.0000 5.9674 7,400 5,600 12,000 9,200
Torque Coefficients Dry: 0.20

Lubricated: 0.15

Torque Tables
(continued)
Alloy Socket Head Cap

Fastener Information SAE J429 Grade 8
Screws ASTM A574
(n) Area (ft-lb) (ft-lb) (ft-lb) (ft-lb)
(in2)
1/4 UNC 20 0.2500 0.0318 12 9 14 10

UNF 28 0.2500 0.0364 14 10 16 12
5/16 UNC 18 0.3125 0.0524 25 18 29 22

UNF 24 0.3125 0.0581 27 20 32 24
3/8 UNC 16 0.3750 0.0775 44 33 51 38

UNF 24 0.3750 0.0878 49 37 58 43
7/16 UNC 14 0.4375 0.1063 70 52 82 61

UNF 20 0.4375 0.1187 78 59 91 68
1/2 UNC 13 0.5000 0.1419 110 80 120 93

UNF 20 0.5000 0.1600 120 90 140 110
9/16 UNC 12 0.5625 0.1819 150 120 --- ---

UNF 18 0.5625 0.2030 170 130 --- ---
5/8 UNC 11 0.6250 0.2260 210 160 240 180

UNF 18 0.6250 0.2560 240 180 270 200
3/4 UNC 10 0.7500 0.3345 380 280 420 320

UNF 16 0.7500 0.3730 420 320 470 350
7/8 UNC 9 0.8750 0.4617 610 460 680 510

UNF 14 0.8750 0.5095 670 500 750 560
1 UNC 8 1.0000 0.6057 910 680 1,000 770

UNF 12 1.0000 0.6630 1,000 750 1,100 840
1 1/8 UNC 7 1.1250 0.7633 1,300 970 1,400 1,100

7F UNF 12 1.1250 0.8557 1,400 1,100 1,600 1,200
1 1/4 UNC 7 1.2500 0.9691 1,800 1,400 2,000 1,500

UNF 12 1.2500 1.0729 2,000 1,500 2,300 1,700
1 3/8 UNC 6 1.3750 1.1549 2,400 1,800 2,700 2,000

UNF 12 1.3750 1.3147 2,700 2,000 3,000 2,300
1 1/2 UNC 6 1.5000 1.4053 3,200 2,400 3,600 2,700

UNF 12 1.5000 1.5810 3,600 2,700 4,000 3,000
ASTM A354 Grade BD
1 3/4 UNC 5 1.7500 1.8995 5,000 3,700 5,600 4,200

1 3/4 UN 12 1.7500 2.1873 5,700 4,300 6,400 4,800
2 UNC 4 1/2 2.0000 2.4982 7,500 5,600 8,400 6,300

2 UN 12 2.0000 2.8917 8,700 6,500 10,000 7,300
2 1/4 UNC 4 1/2 2.2500 3.2477 11,000 8,200 12,000 9,300

2 1/2 UNC 4 2.5000 3.9988 15,000 11,000 17,000 13,000
2 3/4 UNC 4 2.7500 4.9340 18,000 13,000 23,000 17,000
3 UNC 4 3.0000 5.9674 24,000 18,000 30,000 23,000

Lubricated: 0.15

Operation and Maintenance APPENDIX B - Hydraulic System Anti Spin Components
Extec SBS Cone Crusher. – Appendix B
APPENDIX B - Hydraulic System Anti Spin Components

Anti-Spin Valve Body G1
ANTI-SPIN PRESSURE SUPPLY LINE
Pressure FROM C top 3
Reducing
& Relieving Motor/Pump
M1
Crusher Hydraulic
Supply Relief Cylinders
ANTI-SPIN VALVE BODY

Check
(SIDE VIEW)
ANTI-SPIN VALVE BODY
Kick-Down (FRONT VIEW)
Relief M2
G2
T See Note
Drain See Note
M2
ANTI-SPIN HYDRAULIC LINES
(GEARBOX COVER REMOVED)
CASE DRAIN GEARBOX LUBE Pressure
Test Coupling Pressure
MOTOR 1 MOTOR 2
Test Coupling
(M1) (M2)
TO ANTISPIN HYDRAULIC MOTOR
MOTOR 2
CASE DRAIN
RETURN TO TANK
GEARBOX LUBE
CASE DRAIN
CRUSHER
OIL DRAIN
MOTOR 1
Note: Motor 1 hydraulic line

connection to anti-spin valve is
bleed point for anti-spin circuit.
ANTI-SPIN
HYDRAULIC MOTOR

Extec SBS Cone Crusher – Appendix B
NOTES

Silver Bullet Series Gyrasphere
Wear Liner Replacement
Models 38 • 44 • 52 • 57 • 68
SAFETY
Read and fully understand the precautions contained on the inside front cover of this manual
before operating or servicing the crusher. Also refer to Chapter 1 for important quarry safety
information.
! WARNING
DANGER !!!
Failure to follow the safety precautions shown below may result
• Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power and tag
controls. . .
1. Before performing any lubrication, maintenance, adjustments or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.
• Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading vehicles. Wear
and use personal protective equipment in accordance with all applicable health and safety regulations. Safety goggles, hard
hat, ear plugs and steel toe shoes are mandatory when working near machinery. Wear and use additional personal protective
equipment as required.
• Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support structure. Keep a
safe distance from all moving components.
• Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside. These materials
are under tremendous pressure and may be propelled upwards through the feed opening at any time. On crushers not equipped
with hydraulic clearing, use a pole, hook, grappling device or breaker bar to safely dislodge uncrushable objects.
• Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never remove or
disable safety devices. Maintain all machinery in accordance with manufacturer’s instructions and maintenance schedules.
• Read the operator’s manuals for the equipment that you operate. Be sure that you fully understand all phases of operation for
each machine. A careful and well-trained operator is the best insurance against an accident.
• Refer to the Telsmith Quarry Equipment Safely Guide for important quarry safety information. If your copy of the Safety Guide
is missing, replacement copies may be obtained from your local Telsmith dealer or the Telsmith Parts Department.
• All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and other safety
equipment is the user’s responsibility. Such equipment must be installed wherever appropriate and maintained as required.
• It is the purchaser’s responsibility to ensure that quarry equipment is installed and used in a safe and lawful manner. All
machinery must be operated in compliance with applicable health and safety laws and general standards of reasonable care.
Ver: X44-EN-10407 406

Foreword
INTRODUCTION If factory assistance is required, please contact the Telsmith

Service Department. Service technicians are available by
This manual is a supplement to the crusher operation and telephone from 8:00 a.m. to 4:30 p.m. CST, Monday through
maintenance manual. It contains replacement procedures for Friday, except holidays. To ensure faster response, always
the concave ring and mantle, the two wear surfaces which have your machine’s model and serial numbers ready when
form the crushing crusher. calling.
The procedures included on the following pages are based on
the latest information available at the time of publication. FINDING MODEL AND SERIAL NUMBERS
H ow eve r, d u e t o Te l s m i t h ’s p o l i cy o f c o n t i n u o u s
improvement, features and specifications are subject to Model and serial numbers are located on a data plate attached
change without notice. to the crusher main frame (see graphic below).
Actual dimensions, weights, and clearances may be different

than shown, due to fabrication variables, custom engineering
or optional equipment.
Please note that some features shown in this manual may not
be present on your crusher. Some equipment described may
be optional at extra cost, or available only on selected models.
HOW TO CONTACT EXTEC

Please use the following phone numbers when contacting the
Telsmith factory for product support:
Parts and Service Department: 0800 0181945
Fax: 01283 226465
Parts and Service outside the UK: 0044 817791
Note: If calling from outside the UK, please use the Service
Department phone number when ordering parts.
REQUESTING SERVICE ASSISTANCE 7F

If you have questions about the procedures contained in this
manual, please contact your local Extec dealer. Their
knowledgeable factory-trained personnel are prepared to
answer the most frequently asked maintenance and service
related questions.
ORDERING REPLACEMENT PARTS
For replacement parts information, please refer to the Parts
Catalog supplied with your crusher. This booklet contains
exploded diagrams and parts lists to help you quickly identify
the major components and subassemblies used on your
crusher.
The Parts Catalog is provided with all new crushers. If the
Parts Catalog is lost, additional copies are available from
your local Telsmith dealer or the Telsmith Parts Department.
To ensure that the correct parts are received, always have your
crusher’s model and serial numbers ready when placing your
order.
Ver: BKX38-EN-00001 407

Extec X44 Cone Crusher
OPERATION AND MAINTENANCE

INSTRUCTIONS
This manual contains wear liner replacement procedures only.
For detailed operation and maintenance instructions, please
refer to the Operation and Maintenance Manual provided
with your crusher.
If the Operation and Maintenance Manual is lost, a
replacement copy may be ordered from your local Telsmith
dealer or the Telsmith Parts Department.
SERVICE BULLETINS
Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins (if
present) before starting any maintenance or service work.
SAFETY
All quarry personnel operating or servicing the crusher must
read and fully understand the safety information included in
Chapter 1 of this manual.
In addition, all quarry personnel must read and fully
understand the safety information presented in the Telsmith
Quarry Equipment Safety Guide.
The Safety Guide is provided with all new crushers. If the
Safety Guide has been lost, additional copies may be ordered
from your local Telsmith dealer or the Telsmith Parts
Department.
7F ILLUSTRATIONS
This manual contains some illustrations in which guards,
access panels and other safety equipment has been removed
for instructional purposes or to provide greater clarity.
However, to prevent serious personal injury or death, always
be sure all such equipment is installed before operating the
crusher.
408 Ver: BKX38-EN-00001

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SUPPORT BOWL AND CONCAVE RING. . . . . . . . . . . . . . . . . . . . . . . . . 3
MANTLE HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ver: BKX38-EN-00001 409

APPENDICES
Page
APPENDIX A - TORQUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . 477

APPENDIX B - CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . 475
APPENDIX C - WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
APPENDIX D - LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
APPENDIX E - SEALANTS AND COMPOUNDS . . . . . . . . . . . . . . . . . . 491
APPENDIX F - REMOVAL CLEARANCES . . . . . . . . . . . . . . . . . . . . . 493
APPENDIX G - WEAR LINER WEAR LIMITS . . . . . . . . . . . . . . . . . . . . 495
7F
410 Ver: BKX38-EN-00001

Chapter 1
Safety
CONTENTS
Page
1
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . 326
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
CRUSHER SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
QUARRY SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . 332
MAINTENANCE AND REPAIR SAFETY . . . . . . . . . . . . . . . . . . . . . . . 333
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 335
TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Ver: BKX38-EN-00001 Safety 411

SAFETY OVERVIEW A Note is a basic informational statement or helpful

suggestion. An Important is used to draw attention to a
It is the responsibility of the quarry management team to procedure that must be observed to prevent machine damage
develop a comprehensive safety awareness program, and to or malfunction.
ensure that all quarry workers and support personnel receive
appropriate safety training as required by federal, state and
local regulations.
Safety is basically common sense. There are standard safety
rules, but each situation has its own peculiarities which can
not always be covered by rules. Therefore, quarry personnel
must continually watch for possible safety hazards and be
prepared to take prompt corrective action when necessary. ! DANGER
Failure to observe the precautions contained in this chapter
can result in serious personal injury and even loss of life. As
1 with most industrial work environments, a careful operator is Hazard
the best insurance against an accident. ! WARNING!!!
DANGER Statements
The complete observance of one simple rule would prevent

many unnecessary injuries and deaths each year. This rule is:
“Never attempt to clean, lubricate, repair or adjust any ! CAUTION
DANGER !!!
machinery unless it is stopped and properly locked out.”
Please note that this chapter is only intended as a brief review
of basic quarry safety precautions and procedures. The
general guidelines included in the following paragraphs
should not be considered in lieu of a quarry’s official safety Important Advisory
procedures, insurance company requirements, or applicable Statements
federal, state and local regulations. Note
HAZARD AND ADVISORY STATEMENTS

Throughout this manual, the use of hazard and advisory Figure 1–1. Hazard and Advisory Statements
statements have been emphasized. Examples of these are
7F shown in Figure 1-1.
LOCKOUT/TAGOUT
Hazard Statements
Who Must Use Lockout/Tagout?
The Caution, Warning and Danger statements are hazard
Quarry owners, managers, and safety officers must be aware
statements used to alert workers of unsafe practises and
of OSHA’s “lockout/tagout” standard: CRF Section 29
potentially harmful or life-threatening situations. Each of
1910.147, The Control of Hazardous Energy. This standard is
these statements is preceded by the Safety Alert Symbol.
also recognized by MSHA.
• Failure to follow the instructions contained in a Caution
All mechanics, maintenance personnel, operators, and
statement may result in MINOR PERSONAL INJURY.
electricians must fully understand and comply with this
• Failure to follow the instructions contained in a Warning standard to ensure the safety of all employees.
statement could result in SERIOUS PERSONAL INJURY
or DEATH. What is Lockout/Tagout?
• Failure to follow the instructions contained in a Danger Lockout/tagout is a means to ensure that personnel who
statement will result in SEVERE PERSONAL INJURY or install, operate, repair, maintain, service or otherwise disable
DEATH. machines, equipment, or electrical energy systems are
protected from harm due to unexpected energizing, or the
Advisory Statements release of stored energy by...
The Note and Important statements are advisory statements 1. Lockout – Placing a disconnect switch, circuit breaker,
which relate to equipment operation, maintenance and service valve, or other energy-isolating mechanism in the off or
procedures. They are used to draw attention to proper safe position and securing it with a lock so the energy-
procedures and practises. isolating mechanism cannot be activated.
412 Safety Ver: BKX38-EN-00001

2. Tagout – A prominent written warning (tag or label) Warn all employees that the machinery is about to be shut
placed on the energy-isolating mechanism indicating the down.
name of the individual placing the mechanism out-of-
2. Shutdown the equipment – After warning all
service, and stating that the energy isolating mechanism
employees, shut down the machine, equipment, or electrical
cannot be activated until the tagout device is removed.
system by the normal stopping procedure.
When Must Lockout/Tagout Occur? 3. Control stored energy – any potentially hazardous
Lockout/tagout must occur whenever service or maintenance stored energy (electrical, mechanical, hydraulic, pneumatic,
is performed, and injury could occur due to the unexpected etc.) that remains must be released, dissipated, restrained, or
start-up of equipment, or the release of stored energy. See otherwise rendered safe. If stored energy reaccumulates,
Figure 1-2. monitor it until the possibility of accumulation no longer
exists.
In general, lockout/tagout procedures must be performed
under the following circumstances: 4. Isolate the equipment – Disengage all isolating devices,
both primary and secondary, so that the equipment is isolated
• Before cleaning, lubricating, adjusting or repairing from all of its energy sources (electrical, mechanical, 1
machinery or equipment. hydraulic, pneumatic, etc.).
• Before working on electrical, hydraulic or pneumatic 5. Apply lockout/tagout devices – Attach lockout tagout
circuits or devices. devices (according to your company’s safety program) in such
• Before clearing jammed mechanisms, machinery or a manner that the isolating device (circuit breaker, control,
equipment. etc.) will be held in a safe or off position. Attach tags to alert
others that the machinery is being serviced.
• Before removing guards or other protective devices.
6. Verify that equipment is isolated – After warning all
• Whenever a machine or its controls will be left unattended. employees to stay clear, engage the start button to confirm the
How is Lockout/Tagout Performed? machine is inoperable. Return the control to the off position
before proceeding with servicing.
OSHA has identified the following step-by-step lockout/
tagout procedure: When Can Lockout/Tagout Devices be
1. Prepare for shutdown – Before shutting down a piece of
Removed?
equipment, know the type and magnitude of the energy that Lockout/tagout devices can only be removed after the
powers it, the hazards of that energy, and how to control it. following conditions are met:
LOCKOUT / TAGOUT POWER... 7F

• Before making inspections or adjustments.
• Before performing any lubrication, maintenance or repairs.
Crusher lockout/tagout summary:
1. Always lockout/tagout power to crusher drive motor.
2. Always lockout/tagout controls for diesel engine (If equipped).
Disconnect batteries and shut-off fuel supply.
3. Always lockout/tagout power to crusher lubrication and hydraulic
systems.
4. Always lockout/tagout power to all crusher feed and discharge
equipment, such as feeders, conveyors and screens.
! WARNING!!!
DANGER
Failure to perform lockout/tagout procedures can result
Figure 1–2. Lockout/Tagout

• All guards and protective devices are properly re-installed. times. Except in an emergency situation, only the person
that installs a lock is authorized to remove it.
• All tools and repair equipment are removed from the
equipment and the immediate area. • To prevent accidental start-up, never give your lock or its
key to another employee.
• All mechanics and other personnel are clear of the
equipment and its immediate area. • Your key must open your lock only. Your key should not
be capable of opening any other locks. Keys for other locks
• All personnel have been warned that the equipment is
should not be capable of opening your lock.
about to be restarted (sound warning horn and activate
warning lights). • Except in an emergency situation, never attempt to remove
anyone else’s lock. Do not allow others to remove your
After removing lockout/tagout devices, always use the normal
lock.
start-up procedure as described in the operator’s manual for
the machinery. • If two or more people are working on a machine, a multiple
lockout device must be used to prevent accidental start-up
Lockout/Tagout Devices
1 in the event that one person finishes working before
another.
Lockout/tagout devices include:
1) locks • Each lock must have a tag. If two or more people are
2) tags and labels working on a machine, each person must attach a separate
3) multiple lockout devices tag to their lock. Never attach a lock without a tag.
A lock must be sufficiently durable, so it can withstand the • Never use tags alone. A tag should always be accompanied
environmental conditions (heat, cold, moisture, etc.) around by a lock which prevents the isolating device from
it. A lock must also be strong enough so that it cannot be easily becoming energized.
removed or forced open.
Additional Lockout/Tagout Requirements
A tag or label must be affixed to each lock to alert others that
• Be sure that the power is COMPLETELY turned off. A
service work is in progress. Each tag or label must have the
motor may be stopped and locked out. However,
following characteristics:
interlocks, starters, and other supplemental electrical
• Be sufficiently durable to withstand wear and abuse, even components may still be energized. Use a voltmeter and/or
if used in dirty or damp environments. ammeter to verify that all electrical circuits are completely
dead.
• Be securely attached with a cable that is difficult to
remove, cut or tear. • Although lockout/tagout procedures are most commonly
7F • Contain the name of the person that applied it.
associated with electrical systems, be aware that hydraulic,
pneumatic and mechanical systems must also be tagged
• Contain a warning or other precautionary statement that and locked out before servicing. This may involve the
briefly indicates why the machine is locked out and what lockout/tagout of valves, levers and other non-electrical
hazards could result if the equipment is started while devices.
service work is in progress.
• For machinery powered by internal combustion engines
When two or more people are working on a piece of (diesel, gas, etc.), always disconnect batteries and shut-off
equipment, a multiple lockout device must be used. This fuel supply before servicing the machinery. Lockout/
allows each person to install their own lock, preventing tagout engine controls to ensure that engine is not
accidental start-up. accidentally started while the machinery is being serviced.
Lockout/Tagout Rules • Always be sure that all hydraulic or air pressure is

completely relieved before working on hydraulic or
• Always lockout/tagout any machinery before performing pneumatic systems. Dangerous pressures can be present,
any adjustment, inspection, lubrication, maintenance or even when equipment is turned off and locked out.
repair procedures. Failure to observe this precaution may
result in serious personal injury or death. • After maintenance or repairs are completed, always warn
all employees that the machinery is about to be restarted.
• Your company’s lockout/tagout program may be Be sure no one is on or near the equipment before a lock
somewhat different than described in this manual. If so, be and tag is removed.
sure to completely follow your company’s official policies
and procedures when lockout/tagout is necessary. Consult • As a precaution, always activate a warning horn or light
your company’s safety officer if you have any questions. before restarting the machinery. This will provide
additional warning for personnel to stay clear of machinery
• A lock must have only one user and one key. Anyone who that is about to be started.
installs a lock must keep the key in their possession at all

CRUSHER SAFETY • Never attempt to manually clear jammed material from the
crushing chamber while the upper frame is in the lowered
• Perform a complete walk around inspection before starting (clamping) position. Any material lodged in the chamber
the crusher. Be sure that no persons are on, inside or under could release without warning, and may be propelled
the crusher. Refer to the Operation and Maintenance upward through the feed opening. Serious injury or death
Manual for crusher daily start-up procedures. could result. Refer to the Operation and Maintenance
• Be sure that all guards and other safety devices are Manual for jam removal procedures.
correctly installed and tightly secured before starting the • Do not tamper with crusher interlock components. Never
crusher. Stay clear of rotating or moving parts during attempt to defeat electrical interlocks or to disable crusher
crusher operation. protective devices.
• Do not allow personnel to be on or near the crusher during • Never place hands on cylinder rods. Stay clear of pinch-
operation. Stay clear of feed and discharge areas to prevent point area between the upper and main frames.
personnel being injured or killed by flying or falling rock.
• Never stand on hydraulic hoses or use them as steps. If
• Rock projected upwards through the feed opening can hoses rupture, serious injury or death could result. As 1
injure or kill. Do not look directly into the feed opening required, use a safety harness during servicing.
while the crusher is operating. Use mirrors or closed-
circuit cameras if close observation of the feed • Always lockout/tagout power to the crusher drive motor,
arrangement is necessary for troubleshooting or evaluation crusher oil lubrication system and crusher hydraulic
purposes. system before performing any inspection, adjustment
lubrication, maintenance or repair procedures. Also
• Never attempt to clear jammed material from the crushing lockout power to all crusher feed and discharge equipment.
chamber while the crusher is operating. Serious injury or Be sure pressure is fully relieved before servicing the
death could result if you are pulled into, or fall inside, the hydraulic system.
crushing chamber.
• If the crusher is powered by a diesel engine, always
disconnect batteries and shut-off fuel supply before
performing any inspection, adjustment, lubrication,
maintenance or repair procedures. Lockout/tagout engine
controls to prevent the engine from being accidentally
started while the crusher is being serviced.
• Support the crusher upper frame with hardwood blocking
or steel safety spacers before entering the crushing
chamber for service work. Never rely on hydraulic
pressure to keep the upper frame raised. You could be
7F
crushed and killed if the upper frame lowers unexpectedly.
• Always stop the crusher immediately if any gauges show
abnormal readings, or if there is a sudden obvious change
in operation. Be alert for noises that might indicate trouble.
• Inspect, lubricate, maintain and repair the crusher in
accordance with the instructions contained in this manual
and any additional manuals or documentation provided
with the crusher.

QUARRY SAFETY SUMMARY • Use respirators in dusty locations and when working with
hazardous substances. Prolonged exposure to rock dust or
Know Your Machinery chemical fumes can cause permanent respiratory illness.
• Read the manufacturer’s operation and maintenance • Other personal protective equipment may be necessary for
manuals for all machinery and equipment that you operate. your specific job assignment, such as a full face shield and
Be sure that all hazard statements contained within the safety harness. Wear or use these items when necessary
manuals are completely understood. and as required by applicable federal state and local
• Become familiar with the controls, functions and settings regulations.
of each machine. Fully understand all phases of each Observe Personal Safety Precautions
machine’s operation.
• Never wear loose or ragged clothing when working on or
• Be sure that you completely understand and follow all around rotating power equipment. Avoid wearing
start-up and shut-down procedures as described in the necklaces, rings or other jewelry. These items can become
manufacturer’s manuals. caught or tangled in the machinery, resulting in severe
1 • Be familiar with the safety signs on your equipment, and personal injury or death.
the hazards against which they warn. • Keep hair short, if possible. Keep long hair securely tied-
• Check the legibility of all safety signs every day. Order up to prevent it from becoming caught in the machinery.
new signs from the machinery manufacturer if they • Be especially careful whenever using wet walkways,
become illegible or worn. platforms, or ramps. The combination of rock dust and wet
Be Prepared for Emergencies metal can create an extremely slippery surface. Keep all
walkways and other access structures clean, dry and free of
• Know the proper emergency shut-down procedures for the grease or oil.
equipment you operate.
• Use walkways and ladders when working near machinery,
• Know where fire extinguishers are kept and how to use or observing its operation. Use a safety harness when
them. Be sure that fire extinguishers are properly rated, and necessary. Keep handrails and machine contact surfaces
that they remain fully charged and ready for use at all clean.
times.
• To avoid back injuries, always use proper lifting
• Know the procedure for contacting emergency medical techniques to safely lift heavy objects. Lift with your legs
personnel. Keep a list of emergency phone numbers handy and keep your back straight. Keep the materials or object
at all times. close to your body. Have a co-worker assist you if the load
7F • Know where first-aid kit, stretcher and other emergency
supplies are kept. Be sure that first aid supplies are
cannot be lifted safely by one person.
• Never attempt to catch falling materials or objects.
properly maintained and ready for use.
• Be aware of flammable liquids and other potential fire
• Make sure that a clear path to emergency equipment and hazards. Do not smoke when refilling engines or using
exits is always maintained. Do not allow equipment, cleaning solvents.
spilled materials or other obstructions to get in the way.
• Do not stand under equipment or components that are
• Know how to report accidents. Always report all accidents being hoisted or suspended. Never allow other quarry
immediately to the appropriate supervisor. personnel to do so.
Wear Personal Protective Equipment (PPE) • Before you assemble, operate, clean, lubricate, or adjust
machinery, be sure to read and understand all procedures
• Wear safety glasses or goggles whenever outside of an
contained in the machinery manufacturer’s manual.
approved operator’s enclosure. Failure to wear appropriate
eye protection can result in permanent eye injuries and loss • Be sure to operate quarry machinery in compliance with
of sight. current OSHA and MSHA regulations, and all applicable
state and local regulations.
• Wear appropriate ear protection when working within 50
feet of any operating quarry machinery, and in other areas
where noise levels are high. Prolonged exposure to high
noise levels can cause permanent hearing loss.
• Wear steel-toe safety boots, heavy-duty gloves and a hard
hat. This equipment is mandatory in most areas of the
quarry.

Help Prevent Accidents Practice Good Housekeeping

• Do not allow unauthorized personnel in or near the work • Do not store tools or equipment on walkways.
area. Never allow unauthorized personnel to operate,
• Be sure that all walkways, platforms, stairs and ramps are
adjust, maintain or repair machinery.
kept free of spilled material and trash. A build-up of
• Allow only properly trained and experienced personnel to material in these areas can cause slips and falls. Make
operate machinery. Be sure inexperienced operators are repairs as required in areas where spillage is present.
carefully supervised at all times.
• Do not allow machinery to become buried under piles of
• Before start-up, visually check that no personnel are inside, spilled material. This will make the machinery more
on, under or beside the machinery. Alert all workers that difficult to inspect and may hide broken welds, loose
start-up is about to occur. Always sound warning horn fasteners and other serious problems that could cause a
before starting the machinery. safety hazard.
• Do not allow personnel to be near loading areas, or • Keep the areas around control panels and machinery free of
anywhere else that falling or ejected material could hit
them.
spilled material. Free access must be maintained at all
times. In the event of an emergency, quick access to
1
controls could prevent injury or death.
• Use extreme caution if the machinery must be operated for
inspection or observation purposes. Stay a safe distance • Clean up spilled fuel or oil immediately to eliminate
from the machinery and wear appropriate personal slipping hazards. If necessary, use an oil absorbent.
protective devices.
• Always be sure that power is tagged and locked out before
• Before making repairs to the machinery, always clear all cleaning spilled material or oils. Never clean-up these
quarry material from the feed and discharge devices items while the machinery is operating.
(feeders, conveyors, chutes, etc.).
Inspect And Maintain Machinery
• In areas which present a danger of falling, use an
appropriate fall protection device, such as a safety harness • Always perform a safety inspection at the beginning of
and lifeline. each shift. Refer to the machinery manufacturer’s
operation and maintenance manuals for detailed pre-start-
• Always report any unsafe conditions or defective up inspection and maintenance procedures.
equipment to the appropriate supervisor.
• Test all warning devices before starting the machinery to
Avoid Alcohol and Other Drugs ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks.
• Do not operate or work near quarry machinery when under
the influence of alcohol or other drugs. These items can
result in reduced alertness and impaired judgement.
• Be sure that any defective components or systems are
properly repaired by a qualified technician before the
7F
Serious personal injury or death could result. machinery is started. Immediately report any serious
problems to the appropriate supervisor.
• Some prescription and non-prescription medications can
cause drowsiness or other adverse side effects. Do not • Before performing inspections or maintenance, always
operate or work near quarry machinery when under the lock out power and tag controls to the machine drive, and
influence of such medications. to all feed and discharge equipment. Warn all personnel
that the equipment is being serviced. Refer to the Lockout/
Be Aware of Your Surroundings Tagout section of this chapter for additional information.
• The quarry / recycling environment contains many • Maintenance inspection procedures are included
situations that are potentially hazardous. Use extreme throughout this manual. Although maintenance is not
caution to avoid being struck by haul trucks, loaders and typically a safety concern, machinery that is regularly
other quarry mobile equipment. maintained and in proper working condition will minimize
• Be aware of idle machinery that could start-up without the occurrence of safety hazards and emergency situations.
warning. Stay clear of such machinery and the immediate
area.
• Be aware of overhead obstructions, such as conveyors,
support structures or power lines.

MACHINERY INSTALLATION SAFETY line across a traffic area, protect the cable with properly
rated bridging.
Foundations
• Be sure that all auxiliary control panels or power supply
Proper foundations and support structures are essential to panels can be securely locked out. This type of panel is
ensure the safe and efficient operation of quarry equipment. mandatary.
• Crushing machinery needs a firm foundation on which to • Maintain adequate overhead clearance from power lines or
operate. This does not need to be a poured pad, but it must other obstructions, particularly when planning to use
not be unstable ground. When selecting the location, be stacking conveyors for stockpiles.
sure that the entire area is as level as possible.
• Be sure that electrical power supplies are located in an area
• Follow all manufacturer’s installation drawings and that will be safe from accidental contact during crushing
specifications when constructing the base pads for operations.
permanent plants.
• Be sure that all connections are in accordance with the
1 Guarding National Electric Code and any applicable state or local
codes.
• Quarry management is responsible for the proper
installation and placement of guards to prevent personnel
from coming in contact with rotating or moving parts.
• In addition to the guards supplied with the machinery,
additional guards and related safety equipment may be
required to comply with OSHA, MSHA and any applicable
local regulations. The proper fabrication, installation and
placement of these items is the user’s responsibility.
• When fabricating guards, refer to MSHA’s Guide to
Equipment Guarding at Metal and Nonmetal Mines.
Additional information can also be provided by the safety
officer at your worksite.
• Never remove guards until the machinery is stopped,
power is locked out, and controls are tagged. Be sure that
guards are properly re-installed before reconnecting
power.
7F Customer Modifications
• Do not modify quarry machinery in any way without prior
approval from the manufacturer. Such modifications may
include (but are not limited to) changing machine speed or
direction of rotation, drilling additional holes and welding
or bolting additional equipment to the machinery.
Electrical Hook-up
! WARNING!!!
DANGER
When installing any electrical equipment, be sure to
completely follow the manufacturer’s instructions.
Failure to observe this precaution could result in a
dangerous electrical shock hazard.
• Be sure that all electrical equipment is properly grounded.
• Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
• Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power

MAINTENANCE AND REPAIR SAFETY • Never attempt to work on a pressurized system while it is
pressurized or in operation.
• Before performing maintenance or repairs on any
! WARNING!!!
DANGER pressurized system:
Always lockout/tagout power to machinery and - Cycle the controls through all operating positions to
conveying equipment before performing any relieve any trapped pressure.
maintenance or repairs. Warn all personnel that the
machinery is being serviced. - Check that ALL pressure is relieved from the system.
Pressure gauges must read zero (0) PSI / bar.
General Precautions
- Lockout and tag all controls. Be sure electrical power is
• To help ensure safe machine operation, use only genuine properly locked out and tagged.
OEM replacement parts that are sold or approved by the
machine’s manufacturer. Use of non-OEM parts may • Allow time for hot hydraulic oil to cool before performing
adversely affect machine operation and could result in an a any maintenance or repairs. Hot oil can cause burns.
hazardous situation. • Before loosening fittings or removing components, always
1
• Always tighten all fasteners to the proper torque as recheck that ALL pressure is relieved from the system.
described in the repair procedures. When torque Pressure gauges must read zero (0) PSI / bar.
specifications are not listed, use the values in the torque • Never attempt to crack a hydraulic fitting while a hydraulic
chart at the back of this manual. Refer to Appendix A of system is pressurized. You could be injured or killed by a
this manual. stream of high pressure oil.
• Be sure all replacement fasteners are of the proper grade • Never have your face near, or stand directly in front of a
and specifications. Replace any worn or damaged hydraulic line when cracking a fitting, even after system
fasteners. pressure has been relieved. Always assume that the line has
pressure.
Electrical Systems
• Use a piece of cardboard to check for hydraulic oil leaks,
• Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
the skin, resulting in serious personal injury.
instructions in the machinery manufacturers’ manuals.
• Clean-up any spilled hydraulic fluid. Hydraulic fluid is
• Allow only trained and licensed electricians to install,
extremely slippery, and can be especially dangerous if
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local regulations. • Repair any leaks immediately. Always relieve system 7F
pressure and lockout/tagout power before tightening
• When servicing an electrical system, work with the power
fittings or making repairs.
locked out and tagged. Always assume that an electrical
system is live until it has been locked out. • Never attempt to adjust pressure relief valves to above the
machinery manufacturer’s recommended settings. Serious
• Always tag and lockout power before removing cables
personal injury and/or equipment damage could result.
with quick-disconnect plugs.
• Do not operate any hydraulic or air system with obviously
• Repair any obviously worn or damaged wires and
worn or damaged, or leaking components. Always replace
connectors.
any defective components immediately.
• Inspect power cables and connections daily for signs of
• Never place hands on hydraulic cylinder rods while
wear, cracked insulation and worn or damaged connectors.
equipment is in operation. Do not step on the hydraulic
Repair or replace as required.
relief cylinder hoses when climbing on the crusher.
• Do not store tools inside electrical cabinets.
• Verify that all tools are grounded with a three wire plug or
double insulated. Be sure that all extension cords are
grounded with a three wire plug.
Pressurized Systems (hydraulic and air)

• Adjust, maintain and repair all pressurized systems only in
accordance with the instructions contained in the
manufacturer’s manuals provided with the machinery.

• Refer to manufacturer’s instructions when recharging • Always remove all jammed material before restarting the
hydraulic accumulators or checking accumulator pressure. machinery. To prevent damage, never attempt to restart a
Allow only trained and certified hydraulic system stalled machine without first removing the jammed
technicians to depressurize, recharge or repair hydraulic material.
accumulators.
• Never use dynamite or other explosives to clear jams.
Welding On Machinery Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur.
• Be sure to provide adequate ventilation when welding
inside enclosed areas to prevent the buildup of hazardous Hazardous Materials
fumes. Special concern should be exercised when welding
• Be aware potentially hazardous chemicals or materials.
chromium, manganese, cadmium, copper, cobalt, lead and
Such items can be harmful if they are improperly used,
nickel, as these materials are considered to be potentially
stored, mixed or transported, or if they are inhaled,
carcinogenic.
swallowed or allowed to contact the skin.
• Be sure to wear the proper welding shield, welding gloves
1 and clothing. Do not wear synthetic fabric clothing or
• Consult your employer’s hazard communications plan for
instructions regarding the proper handling and use of
clothing which could be easily ignited by sparks.
hazardous materials. Read and understand the labels
• Always follow all standard safety procedures when attached to the product containers. Always follow the
welding. Be sure that all systems are shut down, power is instructions carefully.
locked out, and controls are tagged. Provide welding
• Consult the manufacturer’s material data sheet (MMD) for
screens to protect other employees working in the area.
potential hazards and appropriate medical procedures
• Relieve all hydraulic pressure before welding near should an accident occur.
hydraulic components and lines. Cover hydraulic
• Store hazardous materials only in approved containers. Be
components to protect them from weld spatter and sparks.
sure containers are clearly labeled.
• Do not weld near flammable liquids or hydraulic oils.
• To avoid potential health hazards, persons in regular
• Welding lifting eyes or hooks to manganese steel castings contact with hydraulic oils must be aware of the
is strongly discouraged, and should be done only if importance of thorough hygiene, and the proper methods
absolutely necessary. Always use a stainless steel or for handling mineral oils.
manganese weld rod. Never allow personnel to walk or
• Mineral-based hydraulic oils act as solvents on the natural
work underneath castings being lifted or supported.
oils of the skin. Frequent and prolonged skin contact can
7F • Never ground the welder so that the electrical power will

flow through bearings, hydraulic components or electrical
cause dermatitis or severe irritation.
• Always wear suitable protective clothing when handling
equipment. Serious damage could result.
hydraulic oil.
• Be sure all compressed gas cylinders are stored upright,
• Be sure protective clothing and proper wash-up facilities
chained and capped. Turn-off all cylinders when not in use.
are available to all personnel that may come in contact with
Clearing Jammed Material mineral-based hydraulic oils.
• If material becomes jammed in the machinery: • Always dispose of used rags or paper towels in the correct
and safe fashion.
- Immediately stop the machinery.
- Lockout/tagout power. Warn others that the machinery is
being serviced.
- Follow the instructions in the operation and maintenance
manual of the affected equipment. (The jam removal
procedure for Extec X 44 crushers is located in the
Operation and Maintenance Manual).
• To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in
operation.

Disposal Of Excess Fuels, Lubricants And • Be sure to use the correct wire rope for the application.
Liquids • Be sure that the wire rope is inspected regularly following
Quarry personnel are responsible for the proper disposal of the manufacturer’s guidelines.
unused fuels, used lubricating oils, used hydraulic oils, and • Avoid sudden loading in cold weather. Never use frozen
other toxic materials. DO NOT dispose of these materials in wire rope.
an unapproved manner. Follow all applicable federal, state
and local regulations. • Use suitable padding to protect wire rope from sharp
corners or edges.
Flammable and Combustible Liquids
• Avoid dragging wire rope underneath loads or over
• Store flammable liquids in a safe place, away from quarry obstacles.
machinery and personnel. Use approved safety containers
• Never use wire rope that is cut, badly kinked, frayed or
and be sure that they are clearly marked. Containers must
crushed.
be covered when not in use.
• Keep flammable liquids away from sparks, open flame,
• Avoid reverse bends. 1
and other ignition sources. Do not smoke around • Be sure that rope ends are properly sized.
flammable liquids. Always obey posted “no smoking”
• Use thimbles in eye fittings at all times.
signs.
• Watch for local wear. Reposition or shorten wire rope to
• Be familiar with the locations of fire extinguishers
remove the worn section from the area of lifting tension.
throughout the quarry. Be sure they remain accessible at all
times, and are not blocked by obstructions. • Follow the manufacturer’s instructions for lubrication if
using wire rope for lifting purposes.
• Do not use gasoline or other flammable liquids to clean
tools or parts. Use only approved non-flammable solvents. Connecting Or Clamping Wire Ropes
• Always shut-off engines before refueling. Ground fuel When connecting or clamping wire ropes, use one of the
spout against the filler neck to prevent static electricity. following:
Never smoke while refueling.
• Clamp and thimble connections combine both the clamp
• Use only approved safety containers for storing and and thimble in one unit. Clamp and thimble connections
transporting small quantities of flammable liquids. Keep are capable of supporting 80% of the rated wire rope load.
containers covered when not in use.
• Cable clips are the most common way to secure a rope to
a piece of equipment or to make an eye. The cable clip or
HOISTING AND HANDLING SAFETY “Crosby Clip” is made of a U-bolt and saddle. If this type
of clip is used to make an eye, the use of a properly sized
7F
General Precautions
thimble is mandatory. If not, the cable may kink, forming
• Do not allow personnel to work or walk under loads a permanent weak spot.
supported by a crane or hoist.
Chains
• Use appropriate lifting devices to secure the load to the
crane. See the following paragraphs of this section for Chains require careful use, handling and maintenance to
additional information. ensure long life and safe operation.
• Use the correct lifting hooks to support the load. Refer to • Be sure that the correct size chain is being used for the
the Operation and Maintenance Manual for crusher lifting application.
points and procedures.
• Be sure that the chain is inspected regularly following the
• Use extreme caution when operating a crane near power manufacturer’s guidelines.
lines or electrical equipment.
• Do not exceed the crane’s rated load capacity. Always upright).
subtract the weight of the hook block, slings, chains,
• Use suitable padding to protect the chain from sharp
spreader bars and any additional equipment to determine
corners or edges.
the maximum load that can be safely lifted.
• Avoid dragging the chain under loads or over obstacles.
Wire Rope
• Use the proper fittings at all times.
Wire rope requires careful use, handling and maintenance to
ensure long life and safe operation. Always observe the • Watch for local wear. Reposition or shorten chain (as
following precautions. required) to remove the worn section from the area of
tension.

• Inspect links to determine the amount of wear. Refer to

manufacturer’s specifications for wear tolerance ranges.
• Be sure that all connections between chain sections are
completed with properly sized hardware and lifting hooks.
! CAUTION
DANGER !!!
Always follow proper rigging procedures as provid-
ed by the chain manufacturer. The angle of rigging
may decrease the rated lifting capacity.
Fiber Or Synthetic Slings

Slings require careful use, handling and maintenance to
1 ensure long life and safe operation.
• Be sure that slings are rated or coded for the hitch or
application.
• Be sure that slings are inspected regularly following the
manufacturer’s guidelines.
• Slings may be safely used in a temperature range of 20 to
180° F (-6 to 82°C) without decreasing load limits. For
temperatures beyond this range or for wet/frozen slings,
follow manufacturer’s instructions for load reductions.
• Do not use synthetic slings in temperatures exceeding
180°F (82°C).
upright).
TRANSPORTING MACHINERY
7F • Be sure that the machinery is properly secured so that it

cannot vibrate or move during transport. Remove any dirt,
stones or other loose material from the machinery.
• Install shipping brackets, wood blocking or other shipping
materials as directed in the machinery manufacturer’s
manuals. Perform any shipment preparation procedures as
indicated in the manuals.
• Plan your route carefully. Know the clearance height of the
machinery. Be aware of bridges, power lines and steep or
uneven grades. Be aware of any other conditions which
may present hazards or obstructions.
• Be sure that all tractor-trailer components are working and
in good condition. Test all systems (brakes, steering, lights,
etc.) for proper operation and/or adjustment before
beginning the move. Check air pressure in all tires and
replace any tires that are worn or damaged.

Chapter 2
General Instructions
CONTENTS
Page
1
WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . 338
TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . 338
HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . 338
HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
HYDRAULIC SYSTEM SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . 339
DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . 339
Ver: BKX38-EN-00001 General Instructions 423

General Instructions Operation and Maintenance
WORK SAFELY AND USE COMMON SENSE • Clean all parts as removed. Verify that they are free of
cracks, nicks, burrs and other imperfections.
• Refer to Chapter 1 of this manual for important quarry
safety information. Also refer to the Telsmith Quarry • Check clearances and dimensions as instructed in the
Equipment Safety Guide for additional safety precautions. procedures.
• Observe all precautionary statements (DANGER, • Replace any excessively worn or damaged parts.
WARNING, CAUTION, IMPORTANT, and NOTE) that • If possible, take reference photographs of the machinery as
are included within the repair and overhaul procedures. it is disassembled. During reassembly, use the photographs
• Be sure all lifting devices, slings and supports are in good to verify that all parts are correctly reinstalled.
condition and of adequate rated capacity. Refer to
Appendix C for component weights. HANDLING SEALS & MACHINED PARTS
• Keep cleaning solvents and other combustibles away from • Be careful not to cut or damage seals during installation.
heat and open flame. Do not smoke around flammable
• Handle shafts carefully to prevent damage. Do not nick or
1 liquids.
mar finished surfaces.
• Wear appropriate personal protective equipment (PPE).
Keep the work area clean and well organized. • If shafts, bearings or other machined items are to be
removed from the machinery for more than a few days,
• If service assistance is needed, contact your local Telsmith cover them with a protective coating of rust-preventative
dealer or the Telsmith Service Department. lubricant.
TOOLS AND SUPPLIES HANDLING BEARINGS

The following common tools, shop equipment and supplies • Remove any loose dirt from the machinery before
are required to complete the repair and overhaul procedures in exposing bearings. Handle bearings with clean, dry hands.
the following chapters of this manual:
• Use only clean lint-free rags. Use clean tools in clean
• Impact wrench with a 3/4 inch drive minimum, 1 inch surroundings. Use clean solvents and flushing oils.
preferred.
• Install new bearings as removed from packaging without
• Set of sockets and breaker bars, minimum 3/4 inch drive washing. Do not remove bearings from packaging until
with sockets up to 3-1/2 inches. ready to use.
• Cold chisel, 3/4 inch. • Soak used bearings in solvent. Then wash the bearings and
7F • Hammers (various sizes). blow them dry with filtered, moisture-free compressed air.
Dip the bearings in oil immediately after drying to prevent
• Cables, slings, and chains. rust.
• Crane or hoist of adequate capacity.
(Refer to Appendix C for component weights)
! WARNING!!!
DANGER
• Feeler gauge and inside/outside micrometers.
Always wear eye protection and face shield when
• Cleaning solvent. using compressed air.
• Flushing oil. • To prevent bearing damage, do not spin the bearings by
Refer to the Tools and Supplies Required heading at the hand or with compressed air after the bearing surfaces have
beginning of each chapter for additional items needed to dried.
perform specific repair and overhaul procedures.
LUBRICANTS & SEALANTS

Required lubricants and sealants are listed at the beginning of
each chapter under the Tools and Supplies Required heading.
Detailed specifications for these items are located in
Appendixes D and E.
PART IDENTIFICATION & INSPECTION

• Tag and mark all parts during removal and disassembly
procedures.
424 General Instructions Ver: BKX38-EN-00001

Operation and Maintenance General Instructions
USING HEAT • Refer to Chapter 1 for additional safety precautions and

warnings which apply to pressurized systems and related
• When using an oil bath, avoid contact with hot oil. machinery.
• Use an acetylene torch if heat is required to remove an • Refer to the crusher operation and maintenance manual
interference-fit part and it is not practical to use hot oil. for complete hydraulic system operation, maintenance and
Keep flame moving continuously. Do not let flame touch troubleshooting procedures.
the part being removed.
• If a part is to be destroyed by heat, be careful not to damage DISCONNECTING HYDRAULIC LINES
other reusable parts nearby.
• Be careful when using heat and handling hot parts. To
prevent burns, always wear appropriate hand, face and eye
! WARNING!!!
DANGER
protection. Failure to relieve pressure before disconnecting the
power rotator hoses may result in the sudden
HYDRAULIC SYSTEM SAFETY SUMMARY release of pressurized hydraulic oil. Serious 1
personal injury or death can occur if pressurized
hydraulic oil penetrates the skin.
! WARNING!!!
DANGER Observe the following precautions when disconnecting
Lockout/tagout power to the hydraulic control hydraulic lines during maintenance and repair procedures:
console before performing any hydraulic system • Lockout/tagout power to the hydraulic control console
maintenance or repairs. before disconnecting hydraulic lines. Be certain that
trapped pressure is completely relieved before loosening
any hydraulic fittings (see next section of this chapter).
! WARNING!!!
DANGER
• Wear appropriate eye, face and hand protection, when
Before disconnecting the power rotator hoses, be disconnecting hydraulic hoses or loosening hydraulic
certain that any trapped pressure is completely fittings. Wear or use additional personal protective
relieved. Refer to the following sections of this chapter equipment (PPE) as required.
for additional information.
• Always assume that the system is pressurized, even if
Observe the following precautions when performing pressure appears to have been relieved. Some residual
hydraulic system maintenance or repairs: pressure may remain trapped within the system even when
the pressure gauge indicates zero (0) PSI.
• Allow only qualified hydraulic service technicians to
perform hydraulic system troubleshooting and repairs. All • Before disconnecting a hydraulic hose, verify that it is
7F
persons working on the hydraulic system must have relaxed and not stiff. A stiff hose indicates that pressure has
appropriate training and certification. not been relieved.
• Allow only licensed electricians to troubleshoot and repair • Never have your face directly in front of a hydraulic line
hydraulic system electrical components and wiring. when cracking a fitting, even after system pressure has
• Use common sense when observing hydraulic system been relieved. Always assume that the line has pressure.
operation. Be aware of potential hazards at all times. Stay • As hydraulic lines are disconnected, catch any oil leakage
clear of all moving or rotating parts. in an appropriate container.
• Wear appropriate eye, face and hand protection, when • To prevent contamination, cap all ports and hose fittings
troubleshooting or repairing the hydraulic system. Wear or immediately after hydraulic lines are disconnected.
use additional personal protective equipment (PPE) as
required.
• Use a piece of cardboard to check for hydraulic oil leaks, ! WARNING!!!
DANGER
the skin.
The power rotator hoses must be disconnected before
• Avoid unnecessary contact with hydraulic oil. performing some repair and overhaul procedures in this
• Clean-up any spilled hydraulic oil. Hydraulic oil is manual. Before disconnecting hoses, depressurize the power
extremely slippery, and can be especially dangerous if rotator circuit as described in the following steps:
spilled on an elevated walkway or platform. 1. Stop the crusher. Lockout/tagout power to the control
box (Refer to Chapter 1 for complete lockout/tagout
procedures).
Ver: BKX38-EN-00001 General Instructions 425

2. Check the hydraulic pressure gauge. Verify that the

gauge indicates zero (0) PSI. See Figure 2-1.
3. To verify that pressure has been relieved, check that both
power rotator hoses are relaxed and not stiff. A stiff hose
indicates that high pressure remains trapped in the circuit.
7F

NOTES
7F

NOTES
7F

Chapter 3
Support Bowl and Concave Ring
CONTENTS
Page
1
GENERAL SHUTDOWN PROCEDURE (Before Working on Crusher) . . . . . . . 345
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . 345
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
SUPPORT BOWL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 353
MIXING AND POURING SMITHBOND (Concave Ring) . . . . . . . . . . . . . . . 359
Smithbond Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Smithbond Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Mixing and Pouring Directions . . . . . . . . . . . . . . . . . . . . . . . . . . 360
SUPPORT BOWL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . 360
DETERMINING THE BUTTRESS THREAD STYLE . . . . . . . . . . . . . . . . . 361

(Early Style Buttress Threads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

(Late Style Buttress Threads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
RECEIVING HOPPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 366
Ver: BKX38-EN-00001 Support Bowl and Concave Ring 429

Support Bowl and Concave Ring Operation and Maintenance
SUPPORT BOWL
1 CONCAVE RING
7F
430 Support Bowl and Concave Ring Ver: BKX38-EN-00001

Operation and Maintenance Support Bowl and Concave Ring
FINAL INSTALLATION AND ASSEMBLY 367 TOOLS AND SUPPLIES REQUIRED

• Suitable rigging and hoisting equipment
• 5 pound hammer
• Sledge hammer
• Extension brackets (special tools - provided with crusher)
• Eyebolts 3/4-10 UNC 2B (quantity = 3)
GENERAL SHUTDOWN PROCEDURE
• Crowbar
(Before Working on Crusher)
• Hand grinder
1. Stop the material feed. Operate the crusher until the
crushing chamber is completely empty. If necessary, use the • Feeler gauge
hydraulic clearing function to clear the crushing chamber. • Tape measure
2. Lockout/tagout power to the crusher control box. Shut
1
• Cold steel chisel
off fuel supply and disconnect batteries if the crusher is
powered by a diesel engine. Refer to Chapter 1 for detailed • Cleaning solvent
lockout/tagout information and procedures. • Putty
• Moly-based EP-2 grease (refer to Appendix D)
! WARNING!!!
DANGER • Smithbond backing compound (refer to Table 3-1)
Always lockout/tagout power before performing any
maintenance, adjustments, lubrication or repairs.
Failure to lockout/tagout power may result in
serious personal injury or death!
7F

Type “A” KEY:

1. Cap screw
2. Flat washer
3. Receiving Hopper, Outer
3 4. Receiving Hopper, Inner
1 5. Felt Seal
6. Cap screw, Socket Head
2
7. Flat washer
8A. Support Bowl Driver
9. Support Bowl
5
10. Smithbond Backing Compound
6 11. Concave Ring
7 12. Filler Ring
1 8A
13. Tapered Key
14. Wedge, Taper Segment
15. Extension Bracket
16. Nut
17. Drive Ring
18. Locknut Ring
19. Upper Frame
20. Felt Seal
4 21. Ring Gear
Crushers with slotted concave

ring lugs only
7F 13
11
10 14
1 12
2 20
15 Model 38 only
2
17
16 19
2 14
16 18
21
Figure 3–1. Support Bowl and Concave Ring Assembly, Type “A”

Type “B” KEY:

1. cap screw
2. Flat washer
3 3. Receiving Hopper, Outer
4. Receiving Hopper, Inner
1 5. Felt Seal
6. cap screw, Socket Head
2 7. Flat washer
8B. Support Bowl Drive Key
9. Support Bowl
10. Smithbond Backing Compound
11. Concave Ring
12. Filler Ring
4 13. Tapered Key 1
14. Wedge, Taper Segment
15. Extension Bracket
16. Nut
17. Drive Ring
5 18. Locknut Ring
19. Upper Frame
20. Felt Seal
21. Ring Gear
6 Crushers with slotted concave

ring lugs only
7
8B
13 7F
10 11
14
1 12
2
20
15 Model 38 only
2
16 17
19
14
2
18
21
16
Figure 3–2. Support Bowl and Concave Ring Assembly, Type “B”

DESCRIPTION
The concave ring is a replaceable casting that forms the upper
surface of the crushing chamber. It is made from manganese
steel, a wear-resistant alloy that work hardens during Support
crushing. Bowl
The concave ring is mounted inside the crusher support bowl.
Rotation of the support bowl raises or lowers the concave ring,
allowing the crusher discharge setting to be adjusted as
needed.
During crushing, the support bowl is held stationary by a
series of hydraulic locking cylinders and a threaded locknut Locknut
ring. The locknut ring is located just above the upper frame. Ring
1 When energized, the locking cylinders exert an upward force Locking

on the locknut ring that is transmitted to the support bowl. Cylinder
This force lodges the slanted buttress threads of the support
bowl tight against the slanted buttress threads of the upper
frame, preventing any support bowl movement. See Figure 3- Upper
3. Frame
Pressing the manual tramp button on the control panel de-
energizes the hydraulic locking cylinders. This unlocks the
support bowl, allowing it to be turned in the desired direction.
See Figure 3-4.
The open pushbutton rotates the support bowl counter-
clockwise, increasing the discharge setting. The close
Figure 3–3. Support Bowl, Locked Position
pushbutton rotates the support bowl clockwise, decreasing the
discharge setting. Adjustments can be made at any time, even
while crushing. Full locking force resumes immediately when
either pushbutton is released.
Support bowl rotation is achieved by one power rotator
7F mounted on the upper frame. A large ring gear transmits force
from the power rotator(s) to a drive ring weldment which
Support
Bowl
engages and turns the support bowl.
On models 44, one full rotation of the support bowl changes
the discharge setting approximately 1-1/2 inches. On Model
The concave ring is tightly secured to the support bowl by a
series of tapered steel wedges. Smithbond, a special epoxy- Locknut
based backing compound, fills the void area between the Ring
concave ring and the support bowl. Smithbond must be re-
poured whenever the concave ring is replaced. Locking
Cylinder
Concave ring replacement intervals will vary, depending on
the amount and type of material being crushed. However,
replacement should always be performed before the concave Upper
ring becomes cracked or excessively worn. Refer to Appendix Frame
G for additional information.
Figure 3–4. Support Bowl, Unlocked Position

SUPPORT BOWL REMOVAL • lift the support bowl and rotate and lift clear of the concave
ring.
Remove the support bowl from the crusher upper frame as
described in the following steps. Refer to Figures 3-1 and 3-2 • Place the support bowl on suitable pieces of hardwood and
for exploded views and numbered callouts [1-21]. Refer to ensure all of the backing resin is removed from the inside
other figures as indicated. face of the bowl, also ensure that the machined portion of
the bowl is clean and free from damage.
1. Lockout/tagout power. Perform the General Shutdown
Procedure as described earlier in this chapter. Refer to
Chapter 1 for complete lockout/tagout instructions. ! WARNING!!!
DANGER
2. Verify that there is adequate clearance above the crusher Always use suitable rigging and hoisting equipment
for support bowl removal. Refer to Appendix F for removal to stabilize and lift heavy objects. Lifting heavy
clearances. components with inadequate hoisting apparatus
• Slew the feed conveyor 90 degrees to the chassis. can damage machinery and may result in serious
• Lock out & Tagout machine for the next operation

personal injury or death. Refer to Appendix C for
weights.
1
• Remove all excess debris & dust from the upper rock box
• Remove all excess debris & dust from the lower rock box
cap screw
• Remove the ring of bolts holding the upper rock box to the EXTENSION
cone, Using suitable lifting equipment remove & lower to FLAT BRACKET
the floor. WASHER
• Remove the flat plate from between the upper & lower
rock boxes (this plate may be stuck down with silicone
sealant break the seal carefully so not to damage the plate).
• Using suitable equipment lift out the inner rock box liner
liner, this will reveal the concave ring wedges.
• Fit the three guide dogs supplied with the loose tools, these
fit onto he ring of outer bolts which hold the upper rock box
in place (three bolts per guide) these guides help to keep
the inner thread parallel during extraction & refitting.
• Fit the three lifting eyes supplied with the loose tools 7F
• Ensuring all personnel are clear of the machine remove the
FLAT
lockout / Tagout and start the machine.
WASHER
• Press the adjust out button to extract the support bowl keep
this rotating in a counter clockwise direction until an NUT
AUDIBLE CLONK is heard. This is to ensure that the
threads have separated.
• If necessary lockout & tagout and inspect the threads
before trying to lift the support bowl. Figure 3–5. Extension Bracket
(Type “A” Support Bowl Assemblies Only)
• If required repeat the above procedure to wind out the
thread.
• Lockout & Tagout machine & using suitable equipment lift
the support bowl and lower to the ground. This can be
placed on suitable hardwood beams 4 off approximately 3”
square.
• Carefully cut the welds on the taper wedges and drift them
out using a suitable hammer & drift.
• Using a crowbar and lump hammer break the concave ring
free.

.
Figure 3–6. Extension Bracket
(Type “B” Support Bowl Assemblies Only)
cap screw EXTENSION

BRACKET
FLAT
WASHER
FLAT
WASHER
NUT
7F
Cutaway
View
Moly-Based
EP-2
Figure 3–7. Buttress Thread Lubrication
3. Apply a generous amount of moly-based EP-2 grease at

each of the four grease fittings around the upper frame. See
Figure 3-7. Refer to Appendix D for grease specifications.
4.

SUPPORT
BOWL
DRIVE
RING
Figure 3–8. Unthreading the Support Bowl
5. Type “A” support bowl assemblies only: Install 3/4 inch .
eyebolts in the three lifting holes on the support bowl driver

[08A]. Secure the eyebolts with jamnuts.
6. Type “B” support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the top edge of the
support bowl. Secure the eyebolts with jamnuts. 7F
7. Using an appropriate lifting device and cables, carefully
lift the support bowl [09] straight up and remove it from the
upper frame [19]. See Figure 3-11.
Figure 3–9. Support Bowl Lifting Arrangement

Figure 3–10. Support Bowl on Blocking (cutaway view)
IMPORTANT: Do not place timbers beneath the lower

lip of the concave r ing. This area must remain
unobstructed to allow room for concave ring removal.
CONCAVE RING REMOVAL
! WARNING!!!
DANGER
The concave ring can release and drop at any time
after the mounting lugs are cut. To prevent serious
7F personal injury, be sure that all personnel are clear
of the area between the concave ring lower lip and
the ground.
! WARNING!!!
DANGER
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
weights.
8. Using an appropriate lifting device, move the support
bowl [09] to a suitable work area where it can be thoroughly
cleaned and inspected.
9. If present, remove the filler rings [12] from the old
concave ring. Save the filler rings for later use.

CONCAVE RING INSTALLATION

Install a new concave ring as described in the following steps.
Refer to Figures 3-1 and 3-2 for exploded views and
numbered callouts [1-21]. Also refer to other illustrations as
indicated.
1. Using a hammer, chisel and hand grinder, remove all old
Smithbond and accumulated dirt from the interior surface of
the support bowl [1]. Be careful not to nick or scratch the
machined seat of the support bowl.
! CAUTION
DANGER !!!
Provide adequate ventilation when removing parts
backed with Smithbond. Wear an airline respirator 1
to prevent inhalation of fumes when torch cutting,
grinding or chopping.
2. Place the new concave ring [09] on hardwood blocking so
it is raised about 3 to 4 inches off the ground. Be sure that the
concave ring is evenly supported and completely level. See
Figure 3-14.
7F
CUT LUG HERE
Figure 3–12. Concave Ring On Blocking
Note: Quantity of
lugs varies by
crusher model
Figure 3–11. Cutting Concave Ring Lugs

• APPLY GREASE TO
SUPPORT SUPPORT BOWL
BOWL (shaded area only)
1 SUPPORT
BOWL
CONCAVE
RING
• NO GREASE ON
CONCAVE RING
• NO GREASE
MACHINED SEATS: ON SEATS
• NO PAINT
• NO DIRT
• NO GREASE CONCAVE
• NO RUST RING
Figure 3–14. Greasing the Support Bowl
7F Figure 3–13. Seat Inspection

! WARNING!!!
DANGER
3. Carefully inspect the machined seat of the support bowl
[09]. This surface must be clean and dry to ensure a proper Always use suitable rigging and hoisting equipment
seal. Remove any burrs or rough spots with a grinder. See to stabilize and lift heavy objects. Lifting heavy
Figure 3-15. components with inadequate hoisting apparatus
4. Apply a thin coat of grease or heavy oil only to the curved
personal injury or death. Refer to Appendix D for
upper surface of the support bowl [09]. DO NOT apply any
weights.
grease to the machined seat at the bottom. See Figure 3-16.
Refer to Appendix D for grease specifications. 8. Using an appropriate lifting device and cables, suspend
the support bowl over the new concave ring [11]. Align the
IMPORTANT: DO NOT apply any grease to the
slots in the support bowl [09] with the lugs in the concave ring
concave ring.
[11]. See Figure 3-17.
5. FC Models Only: Remove all old Smithbond [10] and
9. Slowly lower the support bowl [09] onto the concave
accumulated dirt from the filler rings [12]. After cleaning,
ring. Allow the concave ring lugs to pass completely through
apply a thin coat of grease to each filler ring. Place the filler
the support bowl slots.
rings around the outer surface of the concave ring [09].
6. Type “A” assemblies only: Install 3/4 inch eyebolts into
the three lifting holes on the support bowl driver [08A].
Secure the eyebolts with jamnuts.
7. Type “B” assemblies only: Install 3/4 inch eyebolts into
the three lifting holes on the top edge of the support bowl [09].
Secure the eyebolts with jamnuts.

.
support bowl [09] in either direction until the concave ring
lugs are centered in between the slots of the support bowl.
Then, fully lower the support bowl onto the concave ring.
11. Remove the lifting cables and eyebolts.
12. Measure the distance from the inner edge of the support
bowl [09] to the top edge of the concave ring [11]. Make
measurements in 4 locations, 90 degrees apart. All four
measurements must be equal. If necessary, shift the concave
ring with a crowbar so that it is centered within the support
bowl. See Figure 3-18.
13. Place the taper segments [14] under the concave ring
lugs. Install tapered keys [13] if used (concave rings with
slotted lugs only).
14. Using a hammer, alternately tap all taper segments [14]
1
into place until they are snug against the machined surface of
the support bowl [09]. Then, using a bar and sledge hammer,
alternately drive the taper segments tight until they will not
move. See Figure 3-19.
IMPORTANT: Be certain that all taper segments are
driven as tight as possible. The concave ring may loosen
during crushing if the taper segments are not adequately
tight.
15. Repeat the measurements made in step 12. Verify that the
concave ring [11] remains centered and has not shifted. If
measurements are unequal, drive the taper segments out, and
repeat steps 12 through 14.
Figure 3–15. Lowering the Support Bowl
onto the Concave Ring
10. Models 44, 52, 57 and 68 only: Raise the support bowl
about 1/2 inch above the concave ring [11]. Slowly rotate the
7F
CONCAVE
RING
CROWBAR
• Make measurements in four places spaced 90° apart.

• All four measurements must be equal.
Figure 3–16. Centering the Concave Ring

TAPER SEGMENT
BAR
CONCAVE
RING 57 Only
44 & 52
1 HAMMER
• Alternately drive the taper segments tight

in pairs.
• See diagrams at right for tightening sequence.

57 Only
• After tightening all taper segments, check that the
concave ring remains centered.
7F
68 Only
Figure 3–17. Taper Segment Installation and Tightening

CONCAVE
SUPPORT BOWL RING
• There must be NO
CLEARNACE between
support bowl and
concave ring.
• Check with feeler

TACK WELD
gauge 360°
(Both Places) 1
Figure 3–18. Checking For Clearance
16. Verify that the machined seat of the concave ring [11] is
TIGHT against the machined seat of the support bowl [09].
Using a feeler gauge, check clearance in several places, 360°
around the lower edge of the support bowl. There should be
no clearance at any point. See Figure 3-20.
17. If any clearance is detected, check again that the concave
ring [11] is not loose or cocked. Also, inspect the machined
seat of the support bowl for wear. Any worn areas should be
sealed with putty to prevent Smithbond leakage from Figure 3–19. Welding the Taper Segments
occurring. (Models 38, 44, 52, 57 and 68)
IMPORTANT: Be certain that the concave ring is

properly installed as described in the previous steps.
Serious damage to the support bowl will occur if the
concave ring is loose or cocked.
18. Models 38, 44, 52 and 57: Tack weld the taper segments
[14] to the concave ring lugs. See Figure 3-21.
7F
19. Model 68 only: Tack weld the tapered keys [13] to the
concave ring lugs. See Figure 3-22.
IMPORTANT: DO NOT weld the taper segments [14] to
the support bowl [09]. Breakage of the concave ring lugs
may occur if this is done.
TACK WELD
(Both Places)
Figure 3–20. Welding the Taper Keys

(Model 68 only)
Table 3-1. Smithbond Quantities, Concave Ring

Quantity Required - (22 Pound Containers)

Crusher
Fine Medium Medium Medium Coarse Ex.
Model
Concave Fine Concave Coarse Concave Coarse
Concave Concave Concave
38S N/A N/A 2 2 2 N/A
38FC 6 N/A 6 N/A 6 N/A
44S N/A N/A 5 N/A 5 5
44FC 4 N/A 5 N/A 5 N/A
52S N/A N/A 8 N/A 6 6
52FC 7 N/A 6 N/A 6 N/A
57S N/A N/A 15 N/A 10 8
1 57FC 18 16 15 12 14 N/A
68S N/A N/A 16 N/A 16 16
68FC 24 N/A 22 N/A 22 N/A
NOTE:
• Smithbond is supplied only in 22 pound containers.
• Quantities shown are approximate. Actual quantities required may vary.
• Consult Telsmith Service Department if your liner configuration is not shown
above.
20. Be sure that an adequate quantity of Smithbond [10] is

available at your worksite. Smithbond is an epoxy-based
backing compound that fills the voids between the support
bowl and the concave ring. Refer to Table 3-1 for the
approximate amount of Smithbond required for your crusher
model.
21. Mix each pail of Smithbond one-at-a-time as described in
the Mixing and Pouring Smithbond section of this chapter.
7F After mixing, pour the Smithbond mixture through the
support bowl slots. See Figure 3-23.
22. Continue mixing and pouring Smithbond until the
Smithbond level is about even with the tops of the support
bowl slots. Pouring time will be reduced if pouring occurs at
several locations around the top of the support bowl.
23. Allow adequate time for the Smithbond to fully harden.
In most climates, at least four hours will be required. In colder
climates, allow eight hours, or let the Smithbond harden
overnight.
Figure 3–21. Pouring Smithbond (concave ring)

MIXING AND POURING SMITHBOND • Ensure that Smithbond is at room temperature (about 70°F)
(Concave Ring) before mixing. If the Smithbond is too cold, it can become
viscous and will have difficulty flowing into small spaces.
Smithbond is an epoxy based material that fills the voids If the Smithbond is too warm, it may harden before it is
between the concave ring and support bowl of the crusher. It completely poured.
provides a solid backing surface that helps prevent the
concave ring from becoming deformed during crushing. • For best results, crusher parts should be between 65°F and
90°F during pouring.
New Smithbond must be poured whenever the concave ring is
replaced. • Subsequent batches required to completely fill the cavity
may be mixed and added at any time. Newly poured
Smithbond will adhere to any Smithbond that has already
Smithbond Safety Precautions hardened.
• Do not mix Smithbond in batches larger than 22 pounds.
! WARNING!!!
DANGER For best results, mix and pour each pail one at time. Do not
Failure to observe the following safety precautions
re-use stirring rods. 1
may result in serious personal injury or death. • Store Smithbond at temperatures below 100°F (38°C).
Smithbond is stable for at least 12 months after its date of
• Mix and pour Smithbond only in a well ventilated area. manufacture. It remains usable for an additional 12
Avoid inhaling fumes. months, but hardening time will increase slightly.
• Wear rubber or plastic gloves when working with
Smithbond. Always wear eye protection. HARDENER CAN
• Avoid unnecessary contact with Smithbond. Using soap

and water, remove any Smithbond which comes in contact
with the skin. Immediately flush eyes with running water if
eye contact occurs.
• Clothes soiled with Smithbond must be laundered before
being re-worn.
• Provide adequate ventilation when removing parts backed PLASTIC PARTITION
with Smithbond. Wear an airline respirator to prevent
inhalation of fumes when torch cutting, grinding or
chopping.
• Read the labels on the Smithbond pail and the Smithbond
COVER 7F
hardener can for additional warnings, directions and safety
precautions.
Smithbond Tips
• Smithbond is shipped in plastic pails. Each pail or “kit”
contains a pre-measured amount of liquid resin. Included
RESIN
separately inside the pail is a small can of liquid hardener
and a stirring rod. See Figure 3-24.
• The amount of Smithbond required varies depending on
crusher model and configuration. Smithbond quantities for
concave ring replacement are listed in Table 3-1 of this
chapter.
• As a precaution, it is recommended that one extra 22 pound STIRRING ROD
pail of Smithbond be ordered whenever concave ring
replacement is necessary.
PAIL
Figure 3–22. Smithbond Kit

Figure 3–23. Mixing Smithbond
Mixing and Pouring Directions SUPPORT BOWL PREPARATION

1. Read and understand all safety precautions and Prepare the support bowl for installation as described in the
instructions on the Smithbond pail and the can of hardener. following steps. Refer to Figures 3-1 and 3-2 for exploded
2. Mix the resin using the stirring rod and a low speed views and numbered callouts [1-21]. Also refer to other
electric drill. Continue stirring the resin for about 5 minutes, illustrations as indicated.
or until it is thoroughly mixed. If necessary, use a sharp tool 1. Be sure that power remains locked-out. Refer to
to break up any crust which has formed. Chapter 1 for complete lockout/tagout instructions.
3. As stirring continues, add the entire contents of the 2. Replace the concave ring if it is cracked, damaged or
7F hardener can into the pail at a slow, continuous rate. Mix until
a uniform color is obtained. Be sure all settled material is
worn beyond its useful life. Refer to the procedures earlier in
this chapter for concave ring removal and installation
thoroughly mixed. See Figure 3-25. procedures.
4. Pour Smithbond IMMEDIATELY after mixing. Do not 3. Remove all dirt, rust and old grease from the buttress
allow Smithbond to stand. Hardening begins quickly and the threads of the support bowl [09], the locknut ring [18] and the
mixture will remain pourable for only about 15 minutes. upper frame [19].
! CAUTION
DANGER !!!
Smithbond may become hot when mixed, especially
if pouring occurs during high ambient temperatures.
Use gloves when handling the Smithbond pail.
Avoid contact with the concave ring while pouring
Smithbond.
5. Mix and pour additional batches of Smithbond as needed
to completely fill the cavity (Repeat steps 1 through 4 as
required).
Figure 3–24. Cleaning the Buttress Threads

DETERMINING THE BUTTRESS THREAD Refer to the following pages of this chapter for support bowl
STYLE installation procedures.
Two different styles of buttress threads are used on Telsmith Installation procedures will vary depending on buttress thread
Gyrasphere crushers. Before reinstalling the support bowl, be style:
sure to identify the buttress thread style used on your crusher. • If the support bowl and locknut ring have “early” style
Refer to Figures 3-31 and 3-32 for buttress thread buttress threads . . . follow the procedure entitled Support
identification. Bowl Installation (early style buttress threads).
• If the support bowl and locknut ring have “late” style
buttress threads . . . follow the procedure entitled Support
Bowl Installation (late style buttress threads).
• If the support bowl has “late” style buttress threads and the
locknut ring has “early” style buttress threads . . . follow
the procedure entitled Support Bowl Installation (early
style buttress threads).
1
IMPORTANT: Failure to follow the proper support bowl
installation procedure for your crusher may result in
permanent damage to the buttress threads. Such
damage is not covered under warranty.
EARLY STYLE (With tapered thread) EARLY STYLE (With tapered thread)
7F
LATE STYLE (With thread cut-out)

LATE STYLE (With thread cut-out)
Figure 3–25. Support Bowl Buttress Threads
Figure 3–26. Locknut Ring Buttress Threads

SUPPORT BOWL INSTALLATION 6. If not done previously, disconnect the locking cylinder
(Early Style Buttress Threads) hose at the hydraulic power unit. Leave all other hoses
connected. Refer to Figure 3-8.
If your crusher is equipped with “early” style buttress threads,
install the support bowl as described in the following steps. 7. If removed, reinstall the extension brackets [15] onto the
Refer to Figures 3-1 and 3-2 for exploded views and drive ring [17]. Secure the extension brackets with cap screws
numbered callouts [1-5]. Also refer to other illustrations as [01], flat washers [02] and nuts [16]. Refer to Figures 3-5 and
indicated. 3-6 for installation details.
1. Be sure that power remains locked-out. Refer to Chapter

1 for complete lockout/tagout procedures. ! WARNING!!!
DANGER
2. Prepare the support bowl [09] for installation as described Always use suitable rigging and hoisting equipment
in the Support Bowl Preparation section of this chapter. to stabilize and lift heavy objects. Lifting heavy
3. Before continuing with this procedure, verify that your components with inadequate hoisting apparatus
1 crusher is equipped with “early” style buttress threads. Refer can damage machinery and may result in serious
to Figures 3-31 and 3-32 for thread identification.
weights.
4. Type “A” support bowl assemblies only: Install 3/4 inch
eyebolts into the three lifting holes on the support bowl driver 8. Using an appropriate lifting device and cables, suspend
[08A]. Secure the eyebolts with jamnuts. the support bowl [09] several inches over the threaded bore of
the locknut ring [18].
eyebolts into the three lifting holes on the top edge of the 9. Slowly rotate the support bowl [09] until the leading end
support bowl [09]. Secure the eyebolts with jamnuts. of its buttress thread is positioned about 6 inches (15.2 cm)
behind the start of the locknut ring buttress thread. See Figure
3-33.
7F
Buttress
Threads
Important: To prevent thread

damage, allow at least 6 inches of
clearance between thread starts
Buttress
Threads
Figure 3–27. Positioning the Support Bowl (early style buttress threads)

10. Visually check that no personnel are on, under, inside or 24. Depress and hold the CLOSE button. Allow the support
beside the crusher. bowl [09] to become threaded within the bore of the upper
frame [19]. The support bowl will move slowly downward as
11. Remove the lockout tagout and start the engine
it rotates.
12. Type “A” support bowl assemblies only: Depress and
25. Type “A” support bowl assemblies only: Continue to
hold the OPEN or CLOSE pushbutton until the keys on the
depress the CLOSE button until the keys on the drive ring [17]
extension brackets [15] become aligned with the keyways on
become fully engaged in the keyways of the support bowl
the support bowl driver [08A].
driver [08A]. See Figure 3-34.
13. Type “B” support bowl assemblies only: Depress and
26. Type “B” support bowl assemblies only: Continue to
hold the OPEN or CLOSE pushbutton until the keyways on
depress the CLOSE button until the support bowl drive keys
the extension brackets [15] become aligned with the support
[08B] become fully engaged in the keyways of the drive ring
bowl drive keys [08B].
[17]. See Figure 3-35.
IMPORTANT: Be sure that the support bowl remains
27. Depress the STOP button. Lockout/tagout power to
level as it is lowered in step 15 or 16. On some crushers,
it may be necessary to loosen the extension brackets
the hydraulic control console. Refer to Chapter 1 for complete 1
lockout/tagout procedures.
slightly to allow key engagement.
28. Remove cap screws [01], flat washers [02] nuts [16] and
14. Type “A” support bowl assemblies only: Slowly lower
extension brackets [15].
the support bowl [09]. Allow the keys on the extension
brackets [15] to enter the keyways in the support bowl driver 29. Install the inner and outer receiving hoppers. Refer to the
[08A]. Continue lowering the support bowl [09] until its Receiving Hopper Installation section of this chapter for
bottom buttress thread is resting on the top buttress thread of procedure.
the locknut ring [18]
15. Type “B” support bowl assemblies only: Slowly lower
the support bowl [09]. Allow the drive keys [08B] to enter the
keyways of the extension brackets [15]. Continue lowering Drive
Ring
the support bowl [09] until its bottom buttress thread is resting Key
on the top buttress thread of the locknut ring [18].
16. Apply a small upward tension on the lifting cables.
Readjust the lifting cables if the support bowl appears cocked
or unevenly supported.
17. Visually check that no personnel are on, under, inside or
beside the crusher.
7F
IMPORTANT: Continue to apply a small upward tension
on the lifting cables as the support bowl is threaded into Support Bowl
Driver Keyway
the locknut ring. Be sure that the support bowl remains
completely level.
18. Depress and hold the CLOSE button. Verify that the
support bowl [09] begins turning slowly clockwise. Allow the
buttress threads of the support bowl [09] to engage the
buttress threads of the locknut ring [18].
19. After the support bowl has rotated about 3/4 turn, release
the CLOSE button.
Figure 3–28. Key and Keyway Engagement
20. Depress the STOP button. Lockout/tagout power to the (Type “A” Support Bowl Assembly)
hydraulic control console. Refer to Chapter 1 for complete
lockout/tagout instructions.
21. Disconnect the lifting cables and remove the eyebolts.
beside the crusher.
Depress the START button.

Drive
Key
Drive Ring
Keyway
Figure 3–29. Key and Keyway Engagement

(Type “B” Support Bowl Assembly)
7F

SUPPORT BOWL INSTALLATION 6. If not done previously, disconnect the locking cylinder
(Late Style Buttress Threads) hose at the hydraulic power unit. Leave all other hoses
connected. Refer to Figure 3-8.
If your crusher is equipped with “late” style buttress threads,
install the support bowl as described in the following steps. 7. If removed, reinstall the extension brackets [15] onto the
Refer to Figures 3-1 and 3-2 for exploded views and drive ring [17]. Secure the extension brackets with cap screws
numbered callouts [1-21] Also refer to other illustrations as [01], flat washers [02] and nuts [16]. Refer to Figures 3-5 and
indicated. 3-6 for installation details.
1. Be sure that power remains locked-out. Refer to Chapter

1 for complete lockout/tagout procedures. ! WARNING!!!
DANGER
2. Prepare the support bowl [09] for installation as described Always use suitable rigging and hoisting equipment
in the Support Bowl Preparation section of this chapter. to stabilize and lift heavy objects. Lifting heavy
3. Before continuing with this procedure, verify that your components with inadequate hoisting apparatus
crusher is equipped with “late” style buttress threads. Refer to can damage machinery and may result in serious
1
Figures 3-31 and 3-32 for thread identification.
weights.
4. Type “A” support bowl assemblies only: Install 3/4 inch
eyebolts into the three lifting holes on the support bowl driver 8. Using an appropriate lifting device and cables, suspend
[08A]. Secure the eyebolts with jamnuts. the support bowl [09] several inches over the threaded bore of
the locknut ring [18].
eyebolts into the three lifting holes on the top edge of the
support bowl [09]. Secure the eyebolts with jamnuts.
7F
Buttress
Threads
Important: To prevent thread

damage, allow at least 6 inches of
clearance between thread starts
Buttress
Threads
Figure 3–30. Positioning the Support Bowl (late style buttress threads)

9. Slowly rotate the support bowl [09] until the leading end 23. Type “B” support bowl assemblies only: Continue to
of the support bowl buttress thread is positioned about 6 depress the CLOSE button until the support bowl drive keys
inches (15.2 cm) behind the start of the locknut ring buttress [08B] become fully engaged in the keyways of the drive ring
thread. See Figure 3-36. [17].
10. Visually check that no personnel are on, under, inside or 24. Depress the STOP button. Lockout/tagout power to
beside the crusher. the hydraulic control console. Refer to Chapter 1 for complete
lockout/tagout procedures.
11. Remove the lock out tagout and start the engine
25. Remove cap screws [01], flat washers [02] nuts [16] and
12. Type “A” support bowl assemblies only: Depress and
extension brackets [15].
hold the OPEN or CLOSE pushbutton until the keys on the
extension brackets [15] become aligned with the keyways on 26. Install the inner and outer receiving hoppers. Refer to the
the support bowl driver [08A]. Receiving Hopper Installation section of this chapter for
procedure.
13. Type “B” support bowl assemblies only: Depress and
1 hold the OPEN or CLOSE pushbutton until the keyways on
the extension brackets [15] become aligned with the support RECEIVING HOPPER INSTALLATION
bowl drive keys [08B]. Reinstall the inner and outer receiving hoppers as described in
IMPORTANT: Be sure that the support bowl remains the following steps. Refer to Figures 3-1 and 3-2 for exploded
level as it is lowered in step 15 or 16. On some crushers, views and numbered callouts [1-21]. Also refer to other
it may be necessary to loosen the extension brackets illustrations as indicated.
slightly to allow key engagement. 1. Be sure that power remains locked-out. Refer to Chapter
14. Type “A” support bowl assemblies only: Slowly lower 1 for complete lockout/tagout procedures.
the support bowl [09]. Allow the keys on the extension 2. Reinstall the support bowl as described in the Support
brackets [15] to enter the keyways in the support bowl driver Bowl Installation sections earlier in this chapter.
[08A]. Continue lowering the support bowl [09] until its
bottom buttress thread is resting on the top buttress thread of
the locknut ring [18]. ! WARNING!!!
DANGER
15. Type “B” support bowl assemblies only: Slowly lower Always use suitable rigging and hoisting equipment
the support bowl [09]. Allow the drive keys [08B] to enter the to stabilize and lift heavy objects. Lifting heavy
keyways of the extension brackets [15]. Continue lowering components with inadequate hoisting apparatus
the support bowl [09] until its bottom buttress thread is resting can damage machinery and may result in serious
7F on the top buttress thread of the locknut ring [18].
16. Measure the support bowl height at all three extension
weights.
brackets [15]. Measurements must be approximately equal in 3. Using an appropriate lifting device and cables, slowly
all three locations. lower the inner receiving hopper [04] straight down into the
IMPORTANT: Be sure that the support bowl is not support bowl [09].
cocked. To ensure proper thread engagement, the 4. Clean the top surface of the drive ring [17] and the mating
support bowl must be completely level as it is threaded surface of the outer receiving hopper [03]. Apply a bead of
into the locknut ring. caulk completely around the drive ring. See Figure 3-37.
17. Disconnect the lifting cables and remove the eyebolt
beside the crusher.
19. Remove the lock out tagout and start the engine
20. Depress and hold the CLOSE button. Verify that the
support bowl [09] begins turning slowly clockwise.
21. Allow the support bowl to become threaded within the
bore of the locknut ring [18] and the upper frame [19]. The
support bowl will move slowly downward as it rotates.
22. Type “A” support bowl assemblies only: Continue to
depress the CLOSE button until the keys on the drive ring [17]
become fully engaged in the keyways of the support bowl
driver [08A].

Caulk
Figure 3–31. Caulk Application

5. If not done previously, coat the felt seal [05] with moly-
based EP-2 grease. Refer to Appendix D for grease
specifications.
6. Using an appropriate lifting device and cables, slowly
lower the outer receiving hopper [03] into the concave ring
[09]. Be sure that bolt holes are aligned.
7. Remove the lifting cables from the outer receiving hopper
[03]. Figure 3–32. Outer Receiving Hopper Installation
8. Using a mallet, evenly tap completely around the edge of FINAL INSTALLATION AND ASSEMBLY
the outer receiving hopper [03] until it is firmly seated against
the top of the drive ring [17]. Secure the hopper with cap 1. Reconnect the locking cylinder hose at the hydraulic
7F
screws [01] flat washers [02] and nuts [16]. Refer to Appendix power unit. Refer to Figure 3-8.
A for torque specifications.
2. Recalibrate the digital display (optional - if equipped).
Refer to the crusher operation and maintenance manual for
instructions.
3. Adjust the crusher discharge setting. Refer to the crusher
operation and maintenance manual for instructions.

NOTES
7F

Chapter 4
Mantle and Head
CONTENTS
Page
1
GENERAL SHUTDOWN PROCEDURE (Before Working on Crusher) . . . . . . . 371
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . 371
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
HEAD & SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
MANTLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
MANTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
MIXING AND POURING SMITHBOND (Mantle) . . . . . . . . . . . . . . . . . . . 382
CHECKING FOR ANTI-SPIN UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 384

(Crushers Without Anti-Spin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

(Crushers With Anti-Spin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
FINAL INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 388
Ver: BKX38-EN-00001 Mantle and Head 455

Mantle and Head Operation and Maintenance
MANTLE, HEAD
AND MAIN SHAFT
1
7F
456 Mantle and Head Ver: BKX38-EN-00001

Operation and Maintenance Mantle and Head
GENERAL SHUTDOWN PROCEDURE TOOLS AND SUPPLIES REQUIRED

(Before Working on Crusher) • Suitable rigging and hoisting equipment
1. Stop the material feed. Operate the crusher until the • Standard open-end wrenches and/or socket wrenches
crushing chamber is completely empty. If necessary, use the
hydraulic clearing function to clear the crushing chamber. • Standard hex wrenches
2. Lockout/tagout power to the crusher control box. Shut • Sledge hammer

off fuel supply and disconnect batteries if the crusher is • Shaft nut wrench*
powered by a diesel engine. Refer to Chapter 1 for detailed
lockout/tagout information and procedures. • Eyebolt, 1-1/4 inch or 1-1/2 inch*
• Crowbar
! WARNING!!!
DANGER • Hand grinder
Always lockout/tagout power before performing any • Tape measure

maintenance, adjustments, lubrication or repairs.
1
• Feeler gauge
Failure to lockout/tagout power may result in
serious personal injury or death! • Cold steel chisel
• Cleaning solvent
• Clay
• Putty
• Shaft nut burning ring (new)
• NLGI #2 Grease (refer to Appendix D)
• Lubricating oil (refer to Appendix D)
• Smithbond backing compound (refer to Table 4-1)
* Supplied with crusher special tools.
7F

DESCRIPTION
The mantle is a replaceable cone-shaped casting that forms the
lower surface of the crushing chamber. It is made from
manganese steel, a wear-resistant alloy that work hardens
during crushing.
To allow adequate room for mantle replacement, the support
bowl assembly must first be removed from the upper frame as
described in Chapter 3.
In addition, it is strongly recommended that the entire head
and shaft assembly be removed from the crusher before
beginning mantle replacement procedures. This will allow the
taper head skirt, the inner piston ring and the upper thrust
bearing to be completely inspected.
1
However, if sufficient overhead lifting clearance is not
available, mantle replacement may be performed with the
head and shaft assembly installed in the crusher. Refer to
Appendix F for clearance requirements.
The mantle is secured by a shaft nut located on the upper
threaded portion of the main shaft. Before the nut is loosened,
a burning ring located between the mantle and the nut must
first be cut away with a torch.
A bar-shaped shaft nut wrench is used to loosen and tighten
the shaft nut during mantle replacement procedures. This
wrench is supplied with the crusher special tools.
Smithbond, a special epoxy based backing compound, fills the
void area between the top surface of the head and the
underside of the mantle. It prevents deformation of the mantle
and helps absorb crushing forces. New Smithbond must be
poured whenever the mantle is replaced.
7F Mantle replacement intervals will vary, depending on the
amount and type of material being crushed. However,
replacement should always be performed before the mantle
becomes cracked or excessively worn. Refer to Appendix G
for additional information.

1A 1A
6A 10
2A 11
3A
7A
4A
4A
5A
1
5A
12
13
7F
SHAFT NUT WRENCH
14A
SERVICE TOOL
LEGEND
1A - cap screw 5A - Nut 9 - Mantle 13 - Main shaft
2A - Shaft Nut Cap (S Only) 6A - Feed Plate (FC Only) 10 - Taper Head 14A - Wrench
3A - Shaft Nut (S Only) 7A - Shaft Nut (FC Only) 11 - Smithbond 15 - (not used)
4A - Flatwasher 8 - Burning Ring 12 - Inner Piston Ring
Figure 4–5. Exploded View, Head and Shaft Assembly (Type “A”)

1B
4B
2B
2B
3B
5B
12
6B
7B
1 8
13
11
7F 10
SHAFT NUT WRENCH
15B
14B
SERVICE TOOL
LEGEND
1B - cap screw 5B - Feed Plate (FC Only) 9 - Mantle 13 - Main Shaft
2B - Flatwasher 6B - Spacer (FC Only) 10 - Taper Head 14B - Wrench
3B - Shaft Nut Cap (S Only) 7B - Shaft Nut 11 - Smithbond 15B - cap screws
4B - cap screw 8 - Burning Ring 12 - Inner Piston Ring
Figure 4–6. Exploded View, Head and Shaft Assembly (Type “B”)

HEAD & SHAFT REMOVAL

Remove the head and shaft assembly as described in the Note: Match marks are required
following steps. only for crushers equipped with
anti-spin option (see Figure 4-19)
Note that two different head and shaft assemblies are used.
The type “A” assembly is shown in Figure 4-1. The type “B”
assembly is shown in 4-2. Refer to the appropriate figure for
exploded views and numbered callouts [1-15]. Also refer to
other illustrations as indicated.
1. Lockout/tagout power. Perform the General Shutdown
Procedure as described earlier in this chapter. Refer to
Chapter 1 for complete lockout/tagout instructions.
2. To provide access, remove the support bowl assembly
from the upper frame. Refer to Chapter 3 for procedure. 1
3. Verify that there is adequate space above the crusher to
allow head and shaft removal. Refer to Appendix F for
removal clearances.
4. Remove any loose dust and dirt from the interior of the
MAIN
crusher. FRAME
HEAD SKIRT
ROTARY
SEAL RING
Figure 4–8. Match Marks (viewed from under crusher)

NOTE: Perform steps 6 and 7 ONLY if your crusher is
equipped with the anti-spin option (see Figure 4-19). If 7F
your crusher is not equipped with the anti-spin option,
skip steps 6 and 7 and go to step 8.
5. At one of the crusher frame arms, measure the distance
between the top of the frame arm and the bottom of the taper
head skirt. See Figure 4-3. Record this measurement for future
use. It will be checked again during reassembly procedures.
6. Near where the measurements were made in step 6, place
match marks on the taper head skirt, the rotary seal ring, the
main frame hub and the main frame liner. These marks will be
used for reference during reassembly procedures. See Figure
4-4.
7. Type “A” head and shaft assemblies only: Remove cap
screws [1A] nuts [5A] and flat washers [4A]. Remove feed
plate [6A] or shaft nut cap [2A]. If necessary, use a cutting
torch to aid removal of parts. Refer to Figure 4-1.
Figure 4–7. Measuring distance from bottom 8. Type “B” head and shaft assemblies only: On S models,
of head skirt to frame arm (for reference) remove cap screw [1B], flatwasher [2B] and shaft nut cap
[3B]. On FC models, remove cap screw [4B], flatwasher [2B],
feed plate [5B] and spacer [6B]. If necessary, use a cutting
torch to aid removal of parts. Refer to Figure 4-2.

9. Install an eyebolt into the tapped hole at the top of the

main shaft [13]. Be sure that the eyebolt is threaded
completely into the hole. Use a 1-1/4 inch eyebolt for models
38 and 44. Use a 1-1/2 inch eyebolt for models 52, 57 and 68.
! WARNING!!!
DANGER EYEBOLT
can damage machinery and may result in serious TAPER HEAD
personal injury or death. Refer to Appendix C for & MANTLE
weights.
1 IMPORTANT: In the following steps, oil adhesion may

cause the thrust bearing top race to temporarily adhere
to the underside of the taper head. To prevent bearing
roller damage, do not lift the taper head more than two
inches while waiting for the race to drop.
10. Attach a lifting cable to the eyebolt. Using an appropriate
lifting device, slowly lift the head and shaft assembly about
two inches.
MAIN SHAFT
11. Wait and listen for the top race to drop. A “thud” should
be heard within a few minutes, indicating that the race has
THRUST BEARING
dropped. Additional time may be required if the ambient TOP RACE

temperature is very cold.
UPPER
NOTE: If the top race does not drop within a few BEARING
minutes, strike the side of the mantle [9] several times CAGE
with a sledge hammer. Listen again for the race to drop.
BOTTOM
12. Using the lifting device, slowly lift the head and shaft RACE
assembly several additional inches. Without reaching under
7F the taper head, visually check that the top race has dropped
and is resting on the bearing cage. Go to step 14 if the race
ROTARY
SEAL
RING
DID NOT drop. Otherwise, go on to step 15.
BAKELITE
! WARNING!!!
DANGER SEAL
Do not reach or work under the taper head while it is

suspended. If the race remains stuck to the Figure 4–9. Head and Shaft Lifting Arrangement
underside of the taper head, use a sling to retain it
as described in step 14. Serious personal injury or 13. If the race did not drop: Without reaching under the
death will result if the race loosens and falls on taper head, loop a sling around the lower end of the main
persons below. shaft [13] and form a noose. Secure the loose end of the sling
to the eyebolt at the upper end of the shaft.
14. Using the lifting device, slowly lift the head and shaft
assembly until it is completely removed from the crusher.

15. Move the head and shaft assembly to an appropriate work .
area and place it on suitable supports.

16. If the top race remains stuck to the underside of the taper
head, place softwood boards or rags beneath the race. These BURNING
materials will help cushion the impact of the race when it falls. RING
DO NOT reach under the taper head when positioning
boards or rags.
17. Cover the exposed area of the crusher interior to prevent
dirt entry.
MANTLE REMOVAL TORCH
Remove the worn mantle from the taper head as described in

the following steps. Refer to figures 4-1 and 4-2 for exploded Figure 4–11. Cutting the Burning Ring
views and numbered callouts [1-15]. Also refer to other
1
IMPORTANT: To avoid heat damage, direct the cutting
illustrations as indicated. torch away from the taper head and the shaft nut during
18. Remove the head and shaft assembly from the crusher as the next step.
described in the previous paragraph of this chapter. Place the 19. Using a torch, cut through the perimeter of the burning
head and shaft assembly on suitable supports. See Figure 4-6. ring [8]. Use the groove in the center of the ring as a guide.
Refer to Appendix C for weights. The ring will collapse when it is cut, relieving pressure on the
shaft nut [3A, 7A or 7B]. See Figure 4-7.
20. Type “A” head and shaft assemblies only: Secure the
shaft nut wrench [14A] to the shaft nut [3A] or [7A] with cap
screws [1A], flat washers [4A] and nuts [5A].
21. Type “B” head and shaft assemblies only: Secure the
shaft nut wrench [14B] to the shaft nut [7B] with cap screws
[15B].
22. Using a sledge hammer, strike the shaft nut wrench until
the shaft nut loosens and begins to turn. Note that the direction
of rotation is COUNTERCLOCKWISE. See Figure 4-8.
23. Strike the mantle [9] with a sledge hammer until it breaks
7F
loose from the taper head [10]. If it is necessary to cut the
mantle loose with a torch, wear and/or use appropriate
personal protective equipment (PPE).
! WARNING!!!
DANGER
Be sure to provide adequate ventilation when
removing parts backed with Smithbond. Wear an
airline respirator to prevent inhalation of fumes
when torch cutting, grinding or chopping.
Figure 4–10. Head and Shaft Assembly on Supports

Warning: Do not
weld on mantle!
LIFTING CABLES
1 MANTLE
Figure 4–12. Loosening the Shaft Nut “U”
24. After the mantle [9] has loosened, remove the shaft nut HOOKS
wrench [14A or 14B] and the shaft nut [3A, 7A or 7B].
! WARNING!!!
DANGER
to stabilize and lift heavy objects. Lifting heavy Figure 4–13. Mantle Lifting Arrangement
can damage machinery and may result in serious INSPECTION
With the head and shaft assembly removed from the crusher,
weights.
make the following checks and inspections. Refer to figures 4-
1, 4-2 and 4-5 for component identification.
! CAUTION
DANGER !!! 1. Inspect the entire surface of the main shaft [13] for wear,
scratches, score marks, cracks, pitting, rust, etc. File or sand
7F Do not weld washers (lifting eyes) to the mantle. The
welds could crack and fail, allowing the mantle to
any rough areas.
drop. Support and lift the mantle only as described 2. Inspect the inner piston ring [12]. File or sand any rough
in the following steps. areas. Replace the piston ring if it is cracked or damaged.
Thoroughly clean the interior of the piston ring groove.
25. Support the mantle [9] with lifting cables and evenly
spaced U-hooks. Refer to Figure 4-9. If this lifting 3. Inspect the upper Bakelite seals for wear. Replace the
arrangement is not possible, use a crowbar to pry-up one side seals if worn or damaged.
of the mantle. Then, insert a sling between the mantle and the
4. Inspect the upper thrust bearing components for wear,
taper head [10].
scratches, score marks, cracks, pitting, rust, etc. If necessary,
26. Using a suitable lifting device, carefully lift and remove replace the upper thrust bearing.
the mantle [9] from the taper head [10]. If it remains stuck to
5. Inspect the inner bronze sleeve (located inside the
the head, rap the mantle with a sledge hammer to loosen it.
eccentric) for wear, burn marks, scratches, etc. Replace the
sleeve if worn or damaged.

MANTLE INSTALLATION
Install a new mantle as described in the following steps. Refer MANTLE
to figures 4-1 and 4-2 for exploded views and numbered
callouts [1-15]. Also refer to other illustrations as indicated. TAPER
HEAD
1. Using a hammer, chisel and hand grinder, remove all old
Smithbond and accumulated dirt from the surface of the taper
head [10]. Be careful not to nick or scratch the machined seat
at the bottom of the taper head.
! WARNING!!!
DANGER
Be sure to provide adequate ventilation when
removing parts backed with Smithbond. Wear an
airline respirator to prevent inhalation of fumes
• Apply thin coat of grease to
shaded area only!
1
when torch cutting, grinding or chopping.
Figure 4–15. Greasing the Taper Head
MANTLE ! WARNING!!!
DANGER
TAPER
HEAD Always use suitable rigging and hoisting equipment
weights.
! CAUTION
DANGER !!!
MACHINED SEATS: Do not weld washers (lifting eyes) to the mantle. The
• NO PAINT welds could crack and fail, allowing the mantle to
• NO DIRT
• NO GREASE
drop. Support and lift the mantle only as described
in the following steps.
7F
• NO RUST
4. Attach lifting cables and hooks to the new mantle [9].
Figure 4–14. Seat Inspection Using an appropriate lifting device, carefully lower the mantle
onto the taper head [10]. Refer to Figure 4-9 for lifting
2. Inspect the machined seat of the taper head [10]. Remove arrangement.
any burrs or rough spots with a grinder. This surface must be
clean and dry to ensure a proper seal. See Figure 4-10. 5. Place the new burning ring [8] around the threaded
portion of the main shaft [13]. Center it on the upper lip of the
3. Apply a thin coat of grease to the unmachined upper mantle [9]. See Figure 4-12.
surface of the taper head [10]. DO NOT apply any grease to
the machined seat at the bottom portion of the taper head. See 6. Install the shaft nut [3A, 7A or 7B] onto the threaded
Figure 4-11. portion of the main shaft [13].

MANTLE
SHAFT
• Measure in four places, 90° apart.

• All four measurements must be equal.
Figure 4–16. Centering the Mantle
7. Type “A” head and shaft assemblies only: If removed,

secure the shaft nut wrench [14A] to the shaft nut [3A or 7A]
with cap screws [1A], flat washers [4A] and nuts [5A].
7F 8. Type “B” head and shaft assemblies only: If removed,
secure the shaft nut wrench [14B] to the shaft nut [7B] with
cap screws [15B].
9. Hand tighten the shaft nut until is snug against the
MANTLE
burning ring [8]. Then, strike the shaft nut wrench [14A or
14B] with a sledge hammer until the shaft nut stops turning
and cannot be additionally tightened. To prevent the mantle
from loosening during crushing, the shaft nut must be as tight
as possible against the burning ring.
10. Using a feeler gauge, check that the machined seat of the
mantle [9] is tight against the machined seat of the taper head TAPER
[10]. Check clearance in several places, 360° around the taper HEAD
head. There should be no clearance at any point. See Figure 4-
12.
IMPORTANT: Carefully inspect the joint between the
mantle and the taper head. Seal any worn areas with • NO CLEARANCE between mantle and taper head.
putty to prevent Smithbond leakage later in this • Check with feeler gauge 360° around mantle.
procedure. If any clearance is detected, check that the
mantle is not loose or cocked. Figure 4–17. Checking For Clearance

Table 4–1. Smithbond Quantities - Mantle

Crusher Quantity Required
Model (22 Pound Containers)
38S 2
38FC 2
44S 2
44FC 3
CLAY POURING
FUNNEL
1
Figure 4–19. Pouring Smithbond

NOTE: 13. Mix a pail of Smithbond as described in the Mixing and
• Smithbond is supplied only in 22 pound containers.
Pouring Smithbond section of this chapter.
• Quantities shown are approximate. Actual quantities
may vary. 14. Slowly pour the Smithbond mixture into the clay pouring
funnel at one of the pouring holes. Allow the Smithbond to
11. Be sure that an adequate quantity of Smithbond [11] is flow into the cavity between the mantle [9] and taper head
available at your worksite. Smithbond is an epoxy-based [10]. Continue pouring until the pail is completely empty. See
backing compound that fills the voids between the mantle and Figure 4-15.
the taper head. Refer to Table 4-1 for the approximate amount
15. Repeat steps 13 and 14 for the other pouring hole. For
of Smithbond required for your crusher model.
best results, pouring should be alternated between the two
12. Form a clay funnel around each of the two pouring holes pouring holes.
near the top of the mantle. Refer to Figure 4-14.
16. Mix and pour additional pails of Smithbond [11] as
described in the previous steps. Continue until the Smithbond
level is even with the tops of the pouring holes. 7F
POUR SMITHBOND 17. Check for Smithbond leakage at the joint between the
THROUGH HOLES IN mantle [9] and the taper head [10]. Seal any leaks with putty.
MANTLE 18. Allow adequate time for the Smithbond to fully harden.
In most climates, at least four hours will be required. In colder
climates, allow eight hours, or let the Smithbond harden
overnight.
19. After the Smithbond has hardened, remove the clay
pouring funnel from each pouring hole. Grind off any excess
Smithbond residue.
20. Weld the burning ring to the mantle. Use four 2-inch
welds spaced 90 degrees apart. Refer to Figure 4-16.
21. Weld the shaft nut to the burning ring. Use four 2-inch
welds spaced 90 degrees apart. Stagger the welds with the
welds made in the previous step. Refer to Figure 4-16.
Figure 4–18. Mantle Pouring Holes (Side View)

.
Smithbond Safety Precautions
MANTLE ! WARNING!!!
DANGER
BURNING RING
Failure to observe the following safety precautions
may result in serious personal injury or death.
• Mix and pour Smithbond only in a well ventilated area.
Avoid inhaling fumes.
SHAFT
NUT • Wear rubber or plastic gloves when working with
Smithbond. Always wear eye protection.
• Avoid unnecessary contact with Smithbond. Using soap
and water, remove any Smithbond which comes in contact
1 with the skin. Immediately flush eyes with running water if
eye contact occurs.
• Clothes soiled with Smithbond must be laundered before
(TOP VIEW) 2" being re-worn.
TYPICAL
• Provide adequate ventilation when removing parts backed
with Smithbond. Wear an airline respirator to prevent
inhalation of fumes when torch cutting, grinding or
chopping.
BURNING RING • Read the labels on the Smithbond pail and the Smithbond
hardener can for additional warnings, directions and safety
precautions.
Smithbond Tips
STAGGER WELDS • Smithbond is shipped in plastic pails. Each pail or “kit”
contains a pre-measured amount of liquid resin. Included
Figure 4–20. Welding the Burning Ring
separately inside the pail is a small can of liquid hardener
22. Type “A” head and shaft assemblies only: Remove cap and a stirring rod. See Figure 4-17.
7F screws [1A], flat washers [4A], nuts [5A], and shaft nut
wrench [14A]. Store the wrench for future use.
• The amount of Smithbond required varies depending on
crusher model and configuration. Smithbond quantities for
23. Type “B” head and shaft assemblies only: Remove cap mantle replacement are listed in Table 4-1 of this chapter.
screws [15B] and shaft nut wrench [14B]. Store the wrench
• As a precaution, it is recommended that one extra 22 pound
and cap screws for future use.
pai l of Smi thb on d be o rd ered when ever m antl e
24. Reinstall the head and shaft assembly in the crusher. replacement is necessary.
Refer to the Head and Shaft Installation section of this chapter
• Ensure that Smithbond is at room temperature (about 70°F)
for procedure.
before mixing. If the Smithbond is too cold, it can become
viscous and will have difficulty flowing into small spaces.
MIXING AND POURING SMITHBOND If the Smithbond is too warm, it may harden before it is
(Mantle) completely poured.
Smithbond is an epoxy based material that fills the voids • For best results, crusher parts should be between 65°F and
between the mantle and the taper head of the crusher. It 90°F during pouring.
provides a solid backing surface that helps prevent the mantle
• Subsequent batches required to completely fill the cavity
from becoming deformed during crushing.
may be mixed and added at any time. Newly poured
New Smithbond must be poured whenever the mantle is Smithbond will adhere to any Smithbond that has already
replaced. hardened.
• Do not mix Smithbond in batches larger than 22 pounds.
For best results, mix and pour each pail one at time. Do not
re-use stirring rods.

• Store Smithbond at temperatures below 100°F (38°C).

Smithbond is stable for at least 12 months after its date of HARDENER CAN
manufacture. It remains usable for an additional 12
months, but hardening time will increase slightly.
Mixing and Pouring Directions

1. Read and understand all safety precautions and
instructions on the Smithbond pail and the can of hardener.
2. Mix the resin using the stirring rod and a low speed
electric drill. Continue stirring the resin for about 5 minutes, PLASTIC PARTITION
or until it is thoroughly mixed. If necessary, use a sharp tool
to break up any crust which has formed.
3. As stirring continues, add the entire contents of the COVER
hardener can into the pail at a slow, continuous rate. Mix until 1
a uniform color is obtained. Be sure all settled material is
thoroughly mixed. See Figure 4-18.
4. Pour Smithbond IMMEDIATELY after mixing. Do not
allow Smithbond to stand. Hardening begins quickly and the
mixture will remain pourable for only about 15 minutes.
RESIN
! CAUTION
DANGER !!!
Smithbond may become hot when mixed, especially
if pouring occurs during high ambient temperatures.
Use gloves when handling the Smithbond pail.
Avoid contact with the mantle while pouring Smith-
bond.
STIRRING ROD
5. Mix and pour additional batches of Smithbond as needed
to completely fill the cavity (Repeat steps 1 through 4 as
required). PAIL
7F
Figure 4–21. Smithbond Kit
Figure 4–22. Mixing Smithbond

CRUSHER WITH ANTI-SPIN UNIT CRUSHER WITHOUT ANTI-SPIN UNIT
Figure 4–23. Checking for Anti-Spin Option
CHECKING FOR ANTI-SPIN UNIT 3. Thoroughly clean the underside of the taper head [10]. Be
sure that the labyrinth grooves are free of dust and dirt.
Before beginning head and shaft installation, check if your
crusher is equipped with the optional anti-spin unit. Refer to 4. Verify that the inner piston ring [12] is properly installed
Figure 4-19. and centered in the groove of the taper head [10].
Head and shaft installation procedures will vary, depending 5. If removed, reinstall the eyebolt into the tapped hole at
on whether your crusher is equipped with or without anti spin. the top of the main shaft [13]. Be sure that the eyebolt is
threaded completely into the hole. Use a 1-1/4 inch eyebolt for
Procedures for both configurations are contained in the Models 38 and 44. Use a 1-1/2 inch eyebolt for models 52, 57
following sections of this chapter. Be sure to follow the and 68.
correct procedure for your crusher.
7F HEAD AND SHAFT INSTALLATION
6. Lubricate the mating surfaces of the main shaft [13] and
the inner bronze sleeve with oil.
(Crushers Without Anti-Spin)
On crushers NOT equipped with anti-spin, reinstall the head THIS SIDE UP
and shaft assembly as described in the following steps. Refer
to Figures 4-1 and 4-2 for exploded views and numbered
callouts [1-15]. Also refer to other illustrations as indicated.
1. Be sure that power remains locked-out. Refer to
2. If removed, clean and reinstall the upper thrust bearing
components. Be sure that the top race is precisely aligned over
the roller cage. Refer to Figures 4-20 through 4-22 for
installation details.
IMPORTANT: Be certain that bearing races are installed Pockets
as shown in Figure 4-21 (Type I bearing races) or 4-22 must face THIS SIDE DOWN
down
(Type II bearing races). Failure to properly install
bearing components will result in bearing failure.
Figure 4–24. Roller Cage Orientation


BEVELED EDGE UP lifting device, carefully suspend the head and shaft assembly
TOP
RACE over the crusher.
8. Align the bottom of the main shaft [13] with the bore of
the inner bronze sleeve. Slowly lower the head and shaft
assembly into the crusher. DO NOT rotate the assembly as it
is being lowered.
ROLLER CAGE 9. Continue lowering the head and shaft assembly until the
underside of the taper head [10] is seated on the top race of the
upper thrust bearing.
10. Remove the lifting cable from the eyebolt.
11. Block the flywheel sheave so that it cannot turn. Rotate
BOTTOM
the taper head [10] by hand. Check that it turns freely and
smoothly in both directions.
1
RACE
IMPORTANT: If the taper head will not move or is very
difficult to turn, the inner piston ring [12] has not entered
BEVELED EDGE DOWN the bore of the rotary seal ring. To set the piston ring in
the bore, strike the mantle with a sledge hammer several
Figure 4–25. Thrust Bearing Installation times. Then, check again for free rotation. If the taper
(Type I bearing races only) head is still difficult to turn, raise the head and shaft
assembly and re-center the piston ring within its groove.
WIDE BEVEL UP 12. Remove the eyebolt from the shaft nut [3A, 7A or 7B].
TOP Store the eyebolt for future use.
RACE
shaft nut cap [2A] or feed plate [6A] with flat washers [4A],
nuts [5A] and cap screws [1A]. Refer to Appendix A for
torque specifications.
14. Type “B” head and shaft assemblies only: On S models,
ROLLER CAGE secure the shaft nut cap [3B] with flatwasher [2B] and cap
screw [1B]. On FC models, secure the spacer [6B] and feed
plate [5B] with flatwasher [2B] and cap screw [4B]. Refer to
7F
Appendix A for torque specifications.
BOTTOM
RACE
WIDE BEVEL DOWN
Figure 4–26. Thrust Bearing Installation

(Type II bearing races only)
! WARNING!!!
DANGER
weights.


(Crushers With Anti-Spin)
On crushers equipped with anti-spin, reinstall the head and
shaft assembly as described in the following steps. Refer to ECCENTRIC
Figures 4-1 and 4-2 for exploded views and numbered callouts HIGH POINT
[1-15]. Also refer to other illustrations as indicated.
1. Be sure that power remains locked-out. Refer to
2. If removed, clean and reinstall the upper thrust bearing
components. Be sure that the top race is precisely aligned over
the roller cage. Refer to Figures 4-20 through 4-22 for
installation details.
1 IMPORTANT: Be sure that bearing components are
installed as shown in Figure 4-21 (Type I bearing races)
or 4-22 (Type II bearing races). Failure to properly install
bearing components will result in bearing failure.
3. Place a long bar down through the bore of the eccentric.
Using the bar, shift the slider plate from side to side until its
rectangular center hole is aligned with the round center hole
of the adapter plate. See Figure 4-23
4. Thoroughly clean the underside of the taper head [10]. Be
sure that the labyrinth grooves are free of dust and dirt.
ECCENTRIC
5. Verify that the inner piston ring [12] is properly installed LOW POINT
and centered in the groove of the taper head [10].
Figure 4–28. Turning the Eccentric
6. Manually turn the eccentric until its highest and lowest
points are aligned with the ends of the slider plate tang groove.
When alignment is correct, the oil duct will be located 90
7F degrees from the tang groove. See Figure 4-24.
7. If removed, reinstall the eyebolt into the tapped hole at
the top of the main shaft [13]. Be sure that the eyebolt is
threaded completely into the hole. Use a 1-1/4 inch eyebolt for
Models 38 and 44. Use a 1-1/2 inch eyebolt for models 52, 57
and 68.
8. Lubricate the mating surfaces of the main shaft [13] and
the inner bronze sleeve with oil.
! WARNING!!!
DANGER
weights.
lifting device, carefully suspend the head and shaft assembly
over the crusher.
Figure 4–27. Centering the Slider Plate

16. Rotate the taper head [10] slowly clockwise by hand.

Verify that it turns freely for at least 1/4 turn. Due to a one-
way valve inside the anti-spin unit, the amount of effort
required will increase gradually as the head is rotated in this
direction.
IMPORTANT: If the taper head is difficult to turn, raise
the head and shaft assembly. Make the following checks
and inspections:
DRIVE • Check that the slider plate is properly positioned (refer
TANG to Figures 4-23 and 4-24).
• Verify that the piston ring is centered within its groove.
SLIDER
PLATE • Be certain that the drive tang is aligned with the slider
GROOVE plate groove. See Figure 4-25. 1
ADAPTER 17. Remove blocking from the flywheel sheave.
PLATE
18. From under the crusher, locate the match marks that were
made prior to head and shaft removal. Refer to Figure 4-4
earlier in this chapter.
19. Verify that all match marks are aligned. If necessary,
rotate the taper head and rotary seal ring so that the match
marks on these components are aligned with the match marks
on the crusher main frame.
20. At the frame arm nearest the match marks, measure the
distance between the top of the frame arm and the bottom of
the taper head skirt. Refer to Figure 4-3 earlier in this chapter.
21. Compare the latest measurement in step 20 with the
earlier measurement made prior to head and shaft removal.
Ve r i f y t h a t b o t h m e a s u r e m e n t s a r e e q u a l . E q u a l
measurements indicate that the head and shaft assembly is
Figure 4–29. Aligning Drive Tang with Groove
10. Align the bottom end of the main shaft [13] with the bore
fully seated, and that the drive tang is engaged in the slider
plate groove. 7F
of the inner bronze sleeve. As it remains suspended, slowly IMPORTANT: If the drive tang has not engaged the
rotate the head and shaft assembly until the drive tang is slider plate groove, the measurement made in step 20
precisely aligned with the drive tang groove on the slider will be approximately 1/2 to 1 inch longer than the earlier
plate. See Figure 4-25. measurement. If this occurs, raise the head and shaft
11. Slowly lower the head and shaft assembly into the assembly and repeat steps 1 through 21.
crusher. To ensure drive tang engagement, DO NOT rotate the
assembly as it is being lowered.
! CAUTION
DANGER !!!
12. Continue lowering the head and shaft assembly until the
underside of the taper head [10] is seated on the top race of the Never reach between the rotary seal ring and the un-
upper thrust bearing. derside of the taper head to check clearance. Seri-
ous personal injury will result if the rotary seal ring
13. Remove the lifting cable from the eyebolt. Rock the head is lowered onto hands or fingers.
slightly to check that the tang has seated into the tang groove.
22. Remove the eyebolt from the shaft nut [3A, 7A or 7B].
14. Block the flywheel sheave so that the eccentric assembly Store the eyebolt for future use.
cannot turn.
15. Rotate the taper head [10] slowly counter-clockwise by shaft nut cap [2A] or feed plate [6B] with flat washers [4A],
hand. Verify that it turns freely for at least one full turn. nuts [5A] and bolts [1A]. Refer to Appendix A for torque
specifications.
24. Type “B” head and shaft assemblies only: On S models,
secure the shaft nut cap [3B] with flatwasher [2B] and cap
screw [1B]. On FC models, secure the spacer [6B] and feed

plate [5B] with flatwasher [2B] and cap screw [4B]. Refer to
Appendix A for torque specifications.
FINAL INSTALLATION AND ASSEMBLY

1. Reinstall the support bowl assembly. Refer to Chapter 3
for procedure.
2. Recalibrate the digital display (optional - if equipped).
Refer to the crusher operation and maintenance manual for
instructions.
3. Adjust the crusher discharge setting. Refer to the crusher
operation and maintenance manual for instructions.
7F

Operation and Maintenance Appendix B - Conversion Tables
Appendix B - Conversion Tables
LINEAR MEASURE SQUARE MEASURE
To Convert Info Multiply by To Convert Info Multiply by

Inches Centimeters 2.54 Sq. Inches Sq. Centimeters 6.452
Feet Meters 0.3048 Sq. Miles Sq. Kilometers 2.59
Centimeters Inches 0.3937 Sq. Centimeters Sq. Inches 0.15499
Millimeters Inches 0.0394 Sq. Meters Sq. Inches 1549.9
Meters lnches 39.37 Sq. Meters Sq. Feet 10.763
Meters Feet 3.2808
CUBIC MEASURE WEIGHT
1
To Convert Info Multiply by To Convert Info Multiply by
Kilograms Pounds 2.2046
Cu. Inches Cu. Centimeters 16.387
Pounds Kilograms 0.4536
Cu. Feet Cu. Meters 0.0283
Pounds/Sq. Kilograms/Sq. 0.0703
Cu. Centimeters Cu. Inches 0.06102
Inch Centimeter
Cu. Meters Cu. inches 610233779.0
Pounds/Sq. Kilograms/Sq. 4.8824
Cu. Meters Cu. Feet 35.314
Foot Meter
DEGREES FAHRENHEIT TO DEGREES CENTIGRADE
F C F C F C F C F C
-30 -34.44 +20 -6.67 +55 +12.78 +90 +32.22 +225 +107.22
-28 -33.33 21 -6.11 56 13.33 91 32.78 230 110.00
-26 -32.22 22 -5.56 57 13.89 92 33.33 235 112.78
-24 -31.11 23 -5.00 58 14.44 93 33.89 240 115.56
-22 -30.00 24 -4.44 59 15.00 94 34.44 245 118.33
-20 -28.89 25 -3.89 60 15.56 95 35.00 250 121.11
-18 -27.78 26 -3.33 61 16.11 96 35.56 255 123.89
-16
-14
-26.67
-25.56
27
28
-2.78
-2.22
62
63
16.67
17.22
97
98
36.11
36.67
260
265
126.67
129.44
7F
-12 -24.44 29 -1.67 64 17.78 99 37.22 270 132.22
-10 -23.33 30 -1.11 65 18.33 100 37.78 275 135.00
-8 -22.22 31 -0.56 66 18.89 105 40.55 280 137.78
-6 -21.11 32 0.00 67 19.44 110 43.33 285 140.55
-4 -20.00 33 +0.56 68 20.00 115 46.11 290 143.33
-2 -18.89 34 1.11 69 20.56 120 48.89 295 146.11
0 -17.78 35 1.67 70 21.11 125 51.67 300 148.89
+1 -17.22 36 2.22 71 21.67 130 54.44 305 151.67
2 -16.67 37 2.78 72 22.22 135 57.22 310 154.44
3 -16.11 38 3.33 73 22.78 140 60.00 315 157.22
4 -15.56 39 3.89 74 23.33 145 62.78 320 160.00
5 -15.00 40 4.44 75 23.89 150 65.56 325 162.78
6 -14.44 41 5.00 76 24.44 155 68.33 330 165.56
7 -13.89 42 5.56 77 25.00 160 71.11 335 168.33
8 -13.33 43 6.11 78 25.56 165 73.89 340 171.11
9 -12.78 44 6.67 79 26.11 170 76.67 345 173.89
10 -12.22 45 7.22 80 26.67 175 79.44 350 176.67
11 -11.67 46 7.78 81 27.22 180 82.22 355 179.44
12 -11.11 47 8.33 82 27.78 185 85.00 360 182.22
13 -10.56 48 8.89 83 28.33 190 87.78 365 185.00
14 -10.00 49 9.44 84 28.89 195 90.55 370 187.78
15 -9.44 50 10.00 85 29.44 200 93.33 375 190.55
16 -8.89 51 10.56 86 30.00 205 96.11 380 193.33
17 -8.33 52 11.11 87 30.56 210 98.89 385 196.11
18 -7.78 53 11.67 88 31.11 215 101.67 390 198.89
19 -7.22 54 12.22 89 31.67 220 104.44 395 201.67
Ver: BKX38-EN-00001 Appendix B - Conversion Tables 475

Appendix B - Conversion Tables Operation and Maintenance
NOTES
7F
476 Appendix B - Conversion Tables Ver: BKX38-EN-00001

Operation and Maintenance Appendix A - Torque Tables
Appendix A - Torque Tables
Fastener Information SAE J429 Grade 2 SAE J429 Grade 5
(n) Area (in-lb)/(ft-lb) (in-lb)/(ft-lb) (in-lb)/(ft-lb) (in-lb)/(ft-lb)
(in2)
1/4 UNC 20 0.2500 0.0318 66 49 100 76

UNF 28 0.2500 0.0364 75 56 120 87
5/16 UNC
UNF
18
24
0.3125
0.3125
0.0524
0.0581
11
13
8
9
17
19
13
14 1
3/8 UNC 16 0.3750 0.0775 20 15 31 23
UNF 24 0.3750 0.0878 23 17 35 26
7/16 UNC 14 0.4375 0.1063 32 24 49 37

UNF 20 0.4375 0.1187 36 27 55 41
1/2 UNC 13 0.5000 0.1419 49 37 75 57

UNF 20 0.5000 0.1600 55 41 85 64
9/16 UNC 12 0.5625 0.1819 70 53 110 82

UNF 18 0.5625 0.2030 78 59 120 91
5/8 UNC 11 0.6250 0.2260 97 73 150 110

UNF 18 0.6250 0.2560 110 83 170 130
3/4 UNC 10 0.7500 0.3345 170 130 270 200

UNF 16 0.7500 0.3730 190 140 300 220
7/8 UNC 9 0.8750 0.4617 170 120 430 320

UNF 14 0.8750 0.5095 180 140 470 360
1 UNC
UNF
8
12
1.0000
1.0000
0.6057
0.6630
250
270
190
210
640
710
480
530 7F
1 1/8 UNC 7 1.1250 0.7633 350 270 800 600
UNF 12 1.1250 0.8557 400 300 890 670
1 1/4 UNC 7 1.2500 0.9691 500 380 1,100 840

UNF 12 1.2500 1.0729 550 420 1,200 930
1 3/8 UNC 6 1.3750 1.1549 660 490 1,500 1,100

UNF 12 1.3750 1.3147 740 560 1,700 1,300
1 1/2 UNC 6 1.5000 1.4053 870 650 2,000 1,500

UNF 12 1.5000 1.5810 980 730 2,200 1,600
ASTM A307 Grade A ASTM A449
1 3/4 UNC 5 1.7500 1.8995 1,400 1,000 2,300 1,700

1 3/4 UN 12 1.7500 2.1873 1,600 1,200 2,600 2,000
2 UNC 4 1/2 2.0000 2.4982 2,100 1,500 3,400 2,600

2 UN 12 2.0000 2.8917 2,400 1,800 4,000 3,000
2 1/4 UNC 4 1/2 2.2500 3.2477 3,000 2,300 5,000 3,800

2 1/2 UNC 4 2.5000 3.9988 4,100 3,100 6,900 5,200
2 3/4 UNC 4 2.7500 4.9340 5,600 4,200 9,400 7,000
3 UNC 4 3.0000 5.9674 7,400 5,600 12,000 9,200

Lubricated: 0.15
Ver: BKX38-EN-00001 Appendix A - Torque Tables 477

Appendix A - Torque Tables Operation and Maintenance
Torque Tables
(continued)
Alloy Socket Head Cap

Fastener Information SAE J429 Grade 8
Screws ASTM A57
(n) Area (ft-lb) (ft-lb) (ft-lb) (ft-lb)
(in2)
1/4 UNC 20 0.2500 0.0318 12 9 14 10

UNF 28 0.2500 0.0364 14 10 16 12
5/16 UNC 18 0.3125 0.0524 25 18 29 22

UNF 24 0.3125 0.0581 27 20 32 24
1 3/8 UNC 16 0.3750 0.0775 44 33 51 38
UNF 24 0.3750 0.0878 49 37 58 43
7/16 UNC 14 0.4375 0.1063 70 52 82 61

UNF 20 0.4375 0.1187 78 59 91 68
1/2 UNC 13 0.5000 0.1419 110 80 120 93

UNF 20 0.5000 0.1600 120 90 140 110
9/16 UNC 12 0.5625 0.1819 150 120 --- ---

UNF 18 0.5625 0.2030 170 130 --- ---
5/8 UNC 11 0.6250 0.2260 210 160 240 180

UNF 18 0.6250 0.2560 240 180 270 200
3/4 UNC 10 0.7500 0.3345 380 280 420 320

UNF 16 0.7500 0.3730 420 320 470 350
7/8 UNC 9 0.8750 0.4617 610 460 680 510

UNF 14 0.8750 0.5095 670 500 750 560
1 UNC 8 1.0000 0.6057 910 680 1,000 770

UNF 12 1.0000 0.6630 1,000 750 1,100 840
7F 1 1/8 UNC 7 1.1250 0.7633 1,300 970 1,400 1,100
UNF 12 1.1250 0.8557 1,400 1,100 1,600 1,200
1 1/4 UNC 7 1.2500 0.9691 1,800 1,400 2,000 1,500

UNF 12 1.2500 1.0729 2,000 1,500 2,300 1,700
1 3/8 UNC 6 1.3750 1.1549 2,400 1,800 2,700 2,000

UNF 12 1.3750 1.3147 2,700 2,000 3,000 2,300
1 1/2 UNC 6 1.5000 1.4053 3,200 2,400 3,600 2,700

UNF 12 1.5000 1.5810 3,600 2,700 4,000 3,000
ASTM A354 Grade BD
1 3/4 UNC 5 1.7500 1.8995 5,000 3,700 5,600 4,200

1 3/4 UN 12 1.7500 2.1873 5,700 4,300 6,400 4,800
2 UNC 4 1/2 2.0000 2.4982 7,500 5,600 8,400 6,300

2 UN 12 2.0000 2.8917 8,700 6,500 10,000 7,300
2 1/4 UNC 4 1/2 2.2500 3.2477 11,000 8,200 12,000 9,300

2 1/2 UNC 4 2.5000 3.9988 15,000 11,000 17,000 13,000
2 3/4 UNC 4 2.7500 4.9340 18,000 13,000 23,000 17,000
3 UNC 4 3.0000 5.9674 24,000 18,000 30,000 23,000

Lubricated: 0.15
478 Appendix A - Torque Tables Ver: BKX38-EN-00001

Operation and Maintenance Appendix C - Weights
Appendix C - Weights
Model 38 Weights – Pounds (Kilograms)

Item 38S 38FC
Crusher - complete and assembled 27520 27520
(12483) (12483)
Crusher - lower Half only 16120 16120
(7312) (7312)
Includes main frame, bronze sleeves, thrust bearings, eccen-
tric, rotary seal ring, head and shaft, mantle, Smithbond,
countershaft box, main drive gear, pinion gear, flywheel 1
sheave, and hyd. relief cylinders.
Crusher - upper half only 11400 11400
(5171) (5171)
Includes upper frame, locknut, locknut cover, support bowl,
concave ring, feed hoppers, Smithbond, and hyd. unlock cyl-
inders.
Main (lower) frame only 8440 8440
(3828) (3828)
Thrust bearing (each) 175 175
(79) (79)
Rotary seal ring with lead 453 453
(205) (205)
Inner bronze sleeve 40 40
(18) (18)
Outer bronze sleeve 96 96
(44) (44)
Eccentric 859 859
Main drive gear

(390)
263
(390)
263
7F
(119) (119)
Bottom cover plate (units without anti-spin only) 121 121
(55) (55)
Anti-spin unit - Includes bottom plate, gearbox, hydraulic 508 508
motor, adapter plate, slider plate and gearbox cover. (230) (230)
Upper frame only 4070 4070
(1846) (1846)
Hydraulic relief cylinder (each) 94 94
(43) (43)
Receiving hopper, outer 557 557
(253) (253)
Receiving hopper, inner 223 223
(101) (101)
Locknut 1431 1431
(649) (649)
Hydraulic locking cylinder (each) 30 30
(14) (14)
Concave support bowl 2663 2663
(1208) (1208)
Concave ring 1300 1300
(590) (590)
CONTINUED ON NEXT PAGE
Ver: BKX38-EN-00001 Appendix C - Weights 479

Appendix C - Weights Operation and Maintenance

Item 38S 38FC
Smithbond for concave ring 44 132
(Typical - Refer to Chapter 3 for exact quantities) (20) (60)
Head and shaft assembly, including taper head, main shaft, 3150 3250
shaft nut, burning ring and mantle. (1429) (1474)
Taper head only 1290 1290
(585) (585)
Main (tapered) shaft only 545 545
(247) (247)
Mantle only 1022 1022
(464) (464)
1 Smithbond for mantle
(Typical - Refer to Chapter 4 for exact quantities)
44
(20)
44
(20)
Countershaft box assembly, including countershaft box, bevel 1150 1150
pinion, countershaft and roller bearings. (521) (521)
Countershaft box 900 900
(408) (408)
Countershaft 125 125
(57) (57)
Bevel pinion gear (countershaft) 60 60
(27) (27)
Flywheel sheave 162 162
(73) (73)
Power rotator assembly, including motor, gearbox and 200 200
adapter plate. (91) (91)
Power rotator mounting bracket 54 54
(24) (24)
Power rotator pinion gear 35 35
(16) (16)
7F Crusher ring gear 780
(354)
780
(354)
Support Bowl Driver Forging (early models only - if equipped) 326 326
(148) (148)
Drive ring weldment 509 509
(231) (231)
Oil lubrication system with water cooler (empty - no oil in tank) 1380 1380
(626) (626)
Oil lubrication system with air-oil cooler (empty - no oil in tank) 1880 1880
(853) (853)
Hydraulic power unit (empty - no oil in tank) 600 600
(272) (272)
V-belt drive guard 520 520
(236) (236)
Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.
480 Appendix C - Weights Ver: BKX38-EN-00001


Item 44S 44FC
(15136) (15317)
Crusher - Lower half only 21187 21587
(9610) (9792)
countershaft box, main drive gear, pinion gear, flywheel
Crusher - Upper half only 12140 12140
1 Includes upper frame, locknut, locknut cover, support bowl,
(5507) (5507)

inders.
(4087) (4087)
(84) (84)
(472) (472)
(18) (18)
(59) (59)
Eccentric 1069 1069
(485) (485)
Main drive gear 263 263
(119) (119)
7F Bottom cover plate (units without anti-spin only) 121

(55)
121
(55)
(1506) (1506)
Hydraulic relief cylinder and manifold (each) 150 150
(68) (68)
(332) (332)
(119) (119)
Locknut 1664 1664
(755) (755)
(14) (14)
(1473) (1473)
(726) (771)


Item 44S 44FC
(1034) (1034)
(290) (290)
(601) (601)
Smithbond for mantle 44 66
1 Countershaft box assembly, including countershaft box, bevel
pinion, countershaft and roller bearings.
1150
(521)
1150
(521)
(408) (408)
(57) (57)
(27) (27)
(145) (145)
(24) (24)
(16) (16)
Crusher ring gear 385 385
(175) (175)
7F Drive ring weldment 960
(435)
960
(435)
(626) (626)
(853) (853)
(272) (272)
(236) (236)


Item 52S 52FC
(22395) (22439)
Crusher - lower Half only 32555 32653
(14766) (14811)

(7593) (7593)
1
inders.
(6123) (6123)
(159) (159)
(647) (647)
(57) (57)
(78) (78)
Eccentric 1550 1550
(703) (703)
(220) (220)
(78) (78) 7F
(1851) (1851)
(92) (92)
(397) (397)
(104) (146)
Locknut 1663 1663
(754) (754)
Hydraulic Locking Cylinder (each) 30 30
(14) (14)
(1406) (1406)
(1234) (1054)


Item 52S 52FC
(2357) (2357)
(571) (571)
(738) (738)
1800
(816)
1800
(816)
(467) (467)
(101) (101)
(73) (73)
(245) (245)
Power Rotator Mounting Bracket 54 54
(24) (24)
(16) (16)
(161) (161)
(620)
1367
(620)
(853) (853)
(1118) (1118)
(581) (581)
(353) (353)


Item 57S 57FC
(33608) (33789)
Crusher - lower half only 44991 45391
(20181) (20589)

(13200) (13200)
1
inders.
(8940) (8940)
(215) (215)
(1062) (1062)
(127) (127)
(127) (127)
Eccentric 2800 2800
(1270) (1270)
(472) (472)
(128) (128) 7F
(4167) (4167)
(95) (95)
Receiving hopper - outer 1292 1292
(586) (586)
Receiving hopper - inner 569 569
(258) (258)
Locknut 5700 5700
(2586) (2586)
(14) (14)
(4256) (4256)
(1814) (1860)


Item 57S 57FC
(2668) (2668)
(777) (777)
(1203) (1203)
2100
(953)
2100
(953)
(680) (680)
(109) (109)
(91) (91)
(340) (340)
(35) (35)
(16) (16)
(562) (562)
(782)
1725
(782)
Support bowl driver forging (early models only - if equipped) 569 569
(258) (258)
(1216) (1216)
(581) (581)
(230) (230)


Item 68S 68FC
(48584) (49310)
Crusher - lower half only 66651 66651
(30232) (30232)

(18352) (19078)
1
inders.
(13410) (13410)
(340) (340)
(339) (339)
(120) (120)
(156) (156)
Eccentric 4400 4400
(1996) (1996)
(1483) (1483)
(134) (134) 7F
(5220) (5220)
(102) (102)
Receiving hopper - outer 1543 1543
(700) (700)
Receiving hopper - inner 306 306
(139) (139)
Locknut 4896 4896
(2221) (2221)
Hydraulic unlock cylinder (each) 122 122
(55) (55)
(5387) (5387)
(2322) (2164)


Item 68S 68FC
(3362) (3362)
(1338) (1338)
(1488) (1488)
2735
(1241)
2735
(1241)
(880) (880)
(169) (169)
(218) (218)
(395) (395)
(35) (35)
(16) (16)
(1331) (1331)
(293)
647
(293)
Support bowl driver forging (early models only - if equipped) 647 647
(293) (293)
(1252) (1252)
(1660) (1660)
(581) (581)
(335) (335)

Appendix D - Lubricants Operation and Maintenance
Appendix D - Lubricants
Lubricating Oil Specifications
Ambient Temperature
Below 40° F Above 40° F
1 (4.5° C) (4.5° C)
Viscosity ISO Grade C-100 C-150
Viscosity AGMA Grade #250.04 3 EP 4 EP
Viscosity SUS @ 100 °F 469 to 575 709 to 871
Viscosity SUS @ 210 °F 61 to 67 74 to 82
Viscosity Index 95 Min. 95 Min.
Timken OK Load (lbs) 60 Min. 60 Min.
Extreme Pressure Agent (EP) Yes Yes
Rust and Oxidation Agent Yes Yes
Copper Strip Corrosion Test Pass Pass
NOTE: Oil must not be corrosive to metals generally used in bearings, gears, shafts,
pumps and housings. Oil must have the least possible effect on rubber seals, synthetic
seals, packings and hoses. Refer to the Gyrasphere Operation & Maintenance Manual
for detailed crusher lubrication procedures and oil capacities.
7F
Hydraulic Oil Specifications
Viscosity ISO Grade 68

Viscosity SUS @ 100 °F 317
Viscosity SUS @ 210 °F 53 to 57
Viscosity Index 95 Min.
API Gravity 29 Min.
Pour Point, °F -10° to +10°
Flash Point, °F 400° to 425°
Anti-Wear Agent Yes
Anti-Foaming Agent Yes
Rust and Oxidation Inhibitor Yes
NOTE: Refer to the Gyrasphere Operation and Maintenance Manual for detailed
hydraulic system maintenance instructions and oil capacities.
489 Appendix D - Lubricants Ver: BKX38-EN-00001

Appendix D - Lubricants Operation and Maintenance
NLGI #2 Grease Specifications
NLGI Grade Number 2

Worked Penetration @ 77° (60 Strokes) 285
Worked Penetration @ 77° (100,00 Strokes) 300
Copper Corrosion Test, 14 Days Pass
1 Wheel Bearing Test @ 275 °F Pass
NOTE: The above grease must contain an extreme pressure (EP) agent that is not
harmful to bronze, brass or lead. For satisfactory lubrication, grease must be
absolutely free from any ingredients which could cause corrosion, and from gritty
material which could produce wear. Grease should also be uniform in texture,
consistency, structure, stability, flow characteristics and lubricating characteristics.
MOLY
EP-2
Moly Based EP-2 Grease Specifications

(Aluminum Complex with Molybdenum Disulfide)
7F
Worked Penetration 265/295
Rust Prevention (ASTM D-1743) Pass
Corrosion Prevention (ASTM D-1261) Pass
Oxidation Stability (ASTM D-942)
Oxygen Absorption (PSI)
After 100 Hours <3
200 Hours <4
300 Hours <5
Oil Viscosity, SUS @ 100 °F 1000
Four Ball Weld Point 800
Wear Scar 0.51 mm
Type of Soap Aluminum Complex
Operating Temperature 0 to 450 °F
490 Appendix D - Lubricants Ver: BKX38-EN-00001

Operation and Maintenance Appendix E - Sealants and Compounds
Appendix E - Sealants and Compounds

The following sealants and compounds are used throughout the repair procedures of this manual. These items or
their equivalents are commonly available at most local supply houses or distributors. Always read and understand
manufacturer’s directions and safety precautions before using any items shown.
Pipe Sealant
Description Manufacturer 1
Loctite® 592 PST® Pipe Sealant, Medium Loctite Corp
Strength, Slow Cure, Anti-Galling.
Part No. 59241.
Thread Locking Compound

Description Manufacturer
Loctite® 242 Threadblocker, Removable

Strength. Part No. 24241.
Loctite Corp.
7F
Loctite® 271 Threadlock, Permanent Loctite Corp.
Strength. Part No. 10T77.
Spray Primer
(for use with Loctite 242 thread locking compound)
Loctite 7471 Locquic® Primer T, Aerosol, Loctite Corp.

Part No. 22477.
Ver: BKX38-EN-00001 Appendix E - Sealants and Compounds 491

Appendix E - Sealants and Compounds Operation and Maintenance
Anti-Seize Compound
Bostik Never-Seez®, Regular Grade, Bostik Corp.

Copper Formula. Meets MIL SPEC A907E.
Silicone Sealant
Red Devil RD ProTM 100% Silicone Sealant. Red Devil, Inc.

Meets MIL SPEC 46106A.
7F Shellac
Bulls Eye Shellac, Clear Sealer & Finish Wm. Zinsser & Co., Inc.
(Conforms to federal spec. TT-S-300A)
492 Appendix E - Sealants and Compounds Ver: BKX38-EN-00001

Operation and Maintenance Appendix F - Removal Clearances
Appendix F - Removal Clearances
1
Type “A” Gear
C
Arrangement
A
B
Type “B” Gear

Arrangement
Note: Check crusher

gear arrangement
before using the table
7F
below.
Support Bowl Removal Clearances

Crusher Dimensions in inches (centimeters)
Crushers With Type “A” Gear Arrangement Crushers With Type “B” Gear Arrangement
Dimension A Dimension B Dimension C Dimension A Dimension B Dimension C
Model 38 104 (264) 67 (170) 5 (13) 106 (269) 67 (170) 5 (13)
Model 44 N/A N/A N/A 104 (264) 67 (170) 5 (13)
Model 52 N/A N/A N/A 116 (295) 76 (193) 5 (13)
Model 57 133 (338) 87 (221) 5 (13) 125 (318) 83 (211) 5 (13)
Model 68 144 (366) 96 (244) 5 (13) 142 (361) 94 (239) 5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering
or fabrication variables. See the inset views above to determine gear arrangement.
Ver: BKX38-EN-00001 Appendix F - Removal Clearances 493

Appendix F - Removal Clearances Operation and Maintenance
1 Type “A” Upper

Frame Assembly
C
A
B
Type “B” Gear

Arrangement
Note: Check crusher

gear arrangement
7F before using the table
below.
Head and Shaft Removal Clearances
Crusher Dimensions in inches (centimeters)
Crushers With Type “A” Gear Arrangement Crushers With Type “B” Gear Arrangement
Dimension A Dimension B Dimension C Dimension A Dimension B Dimension C
Model 38 136 (345) 130 (330) 5 (13) 136 (345) 130 (330) 5 (13)
Model 44 N/A N/A N/A 141 (358) 132 (335) 5 (13)
Model 52 N/A N/A N/A 161 (409) 151 (384) 5 (13)
Model 57 182 (462) 169 (429) 5 (13) 177 (450) 164 (417) 5 (13)
Model 68 203 (516) 188 (478) 5 (13) 201 (511) 186 (472) 5 (13)
NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom
engineering or fabrication variables. See the inset views above to determine gear arrangement.
If crusher is NOT equipped with anti-spin, Dimensions A and B will be approximately 6 inches less than shown.
494 Appendix F - Removal Clearances Ver: BKX38-EN-00001

Operation and Maintenance Appendix G - Wear Liner Wear Limits
Appendix G - Wear Liner Wear Limits
7F
CONCAVE RING WEAR MEASURMENT

1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operator’s manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the concave ring, measure dimension A.
5. Place a straight edge along the concave ring wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the concave ring should be replaced
Ver: BKX38-EN-00001 Appendix G - Wear Liner Wear Limits 495

Appendix G - Wear Liner Wear Limits Operation and Maintenance
7F
MANTLE WEAR MEASURMENT

1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operator’s manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the mantle, measure dimension A.
5. Place a straight edge along the mantle wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the mantle should be replaced.
496 Appendix G - Wear Liner Wear Limits Ver: BKX38-EN-00001

X38 Cone Crusher
Safety Data Sheets
Title- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - COSHH Sheet Reference

1. Exxon Unirex N 3 Grease - - - - - - - - - - - - - - - - - - - - 570317-00 UNIREX N 3
2. Shell Albida Grease EP2- - - - - - - - - - - - - - - - - -ACIYK GB/eng/C 19/03/2005
3. Shell Rimula Signia 10W-40 - - - - - - - - - - - - - - - - ACLI2 IT/eng/C 01/01/2004
4. Shell Tellus Oil 46 - - - - - - - - - - - - - - - - - - - - - ACKQ6 GB/eng/C 29/04/2004
5. Shell Naturelle Fluid HF-M 46 - - - - - - - - - - - - - ACKXR GB/eng/C 09/06/2004
6. Shell Safe Anti Freeze - - - - - - - - - - - - - - - - - - - L84042 Revision 23 08 2004
7. Shell Agricultural Gas Oil - - - - - - - - - - - - - - - - - F32002 Revision 02 10 2002
8. Exol Ethena EP90 Gear Oil - - - - - - - - - - - - - - - - - - - - - - - -2nd October 2002
9. Shell Omala Oil HD 220 - - - - - - - - - - - - - - - - - ACL4X NO/eng/C 09/06/2004
10. Shell Omala Fluid HD 150 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 400915E-1

X38 Cone Crusher

X38 Cone Crusher
--------------------------------------------------------------------------
570317-00 UNIREX N 3
MATERIAL SAFETY DATA BULLETIN
--------------------------------------------------------------------------
--------------------------------------------------------------------------
1. PRODUCT AND COMPANY IDENTIFICATION
--------------------------------------------------------------------------
PRODUCT NAME: UNIREX N 3
20/10/2003
SUPPLIER: Esso Petroleum Company

ExxonMobil House
Ermyn Way, Leatherhead
Surrey, KT22 8UX
UK
Environmental/Health Emergency telephone: 01372 222 000 (UK)

44 1372 222 000 (Ireland)
INTENDED USE: GREASE
--------------------------------------------------------------------------
2. COMPOSITION/INFORMATION ON INGREDIENTS
--------------------------------------------------------------------------
CHEMICAL NAMES AND SYNONYMS: SEVERE TREAT MIN. OILS & ADDITIVES
GLOBALLY REPORTABLE MSDS INGREDIENTS:
Substance Name Approx. Wt% EU Classification

-------------- ----------- ----------------------------
HYDROXYALKYL LONG-CHAIN <1 C;R34 Xn;R22 N;R50/53
ALKENYL IMIDAZOLINE (CAS
27136-73-8)
N-OLEYLSARCOSINE (CAS <1 Xi;R36/38 N;R50/53

110-25-8)
--------------------------------------------------------------------------
3. HAZARDS IDENTIFICATION
--------------------------------------------------------------------------
This product is considered hazardous according to EU regulatory
guidelines (see Section 15).
Symbol: Not applicable.
Risk Phrase(s): R52/53.

X38 Cone Crusher
POTENTIAL HEALTH EFFECTS: Under normal conditions of intended use,

this product does not pose a risk to health. Excessive exposure
may result in eye, skin or respiratory irritation.
POTENTIAL ENVIRONMENTAL EFFECTSHarmful to aquatic organisms, may cause

long-term adverse effects in the aquatic environment.
For further health effects/toxicological data, see Section 11.
NOTE: This product should not be used for any other purpose without
expert advice.
--------------------------------------------------------------------------
4. FIRST AID MEASURES
--------------------------------------------------------------------------
EYE CONTACT: Flush thoroughly with water. If irritation occurs, call
a doctor.
SKIN CONTACT: Wash contact areas with soap and water. Remove and
clean oil soaked clothing daily and wash affected area.
INJECTION INJURY WARNING: If product is injected into or under
the skin, or into any part of the body, regardless of the
appearance of the wound or its size, the individual should be
evaluated immediately by a physician as a surgical emergency.
Even though initial symptoms from high pressure injection may be
minimal or absent, early surgical treatment within the first few
hours may significantly reduce the ultimate extent of injury.
INHALATION: Remove from further exposure. If respiratory irritation,
dizziness, nausea, or unconsciousness occurs, seek immediate
medical assistance. If breathing has stopped, assist ventilation
with mechanical device or use mouth-to-mouth resuscitation.
INGESTION: Not expected to be a problem. Seek medical attention if
discomfort occurs. Do not induce vomiting.
--------------------------------------------------------------------------
5. FIRE-FIGHTING MEASURES
--------------------------------------------------------------------------
EXTINGUISHING MEDIA: Carbon dioxide, foam, dry chemical and water fog.
SPECIAL FIRE FIGHTING PROCEDURES: Water or foam may cause frothing.
Use water to keep fire exposed containers cool. Water spray may
be used to flush spills away from exposures. Prevent runoff from
fire control or dilution from entering waterways or drinking
water supply.
SPECIAL PROTECTIVE EQUIPMENT: For fires in enclosed areas,
firefighters MUST use self-contained breathing apparatus.
UNUSUAL FIRE AND EXPLOSION HAZARDS: None.
COMBUSTION PRODUCTS: Fumes, smoke, carbon monoxide, sulfur oxides,
aldehydes and other decomposition products, in the case of
incomplete combustion.
Flash Point C(F): > 204(400) (ESTIMATED FOR OIL, ASTM D-92 (COC)).
Flammable Limits (approx.% vol.in air) - LELNE, UEL: NE
NFPA HAZARD ID: Health: 0 , Flammability: 1 , Reactivity: 0
--------------------------------------------------------------------------
6. ACCIDENTAL RELEASE MEASURES
--------------------------------------------------------------------------
NOTIFICATION PROCEDURES: Report spills/releases as required to
appropriate authorities. In case of accident or road spill,
contact the Police and Fire Brigade and, if appropriate, the Area
Water Authority.
PROCEDURES IF MATERIAL IS RELEASED OR SPILLED:
LAND SPILL: Shut off source taking normal safety precautions.

X38 Cone Crusher
Take measures to minimize the effects on ground water. Recover

by pumping or contain spilled material with sand or other
suitable absorbent and remove mechanically into containers. If
necessary, dispose of adsorbed residues as directed in Section
13.
WATER SPILL: Confine the spill immediately with booms. Warn
other ships in the vicinity. Notify port and other relevant
authorities. Remove from the surface by skimming or with
suitable absorbents. If permitted by regulatory authorities the
use of suitable dispersants should be considered where
recommended in local oil spill procedures.
ENVIRONMENTAL PRECAUTIONS: Prevent material from entering sewers,
water sources or low lying areas; advise the relevant authorities
if it has, or if it contaminates soil/vegetation.
PERSONAL PRECAUTIONS: See Section 8
--------------------------------------------------------------------------
7. HANDLING AND STORAGE
--------------------------------------------------------------------------
SPECIFIC USES: GREASE
HANDLING: High pressure injection under the skin may occur due to the
rupture of pressurized lines. Always seek medical attention. No
special precautions are necessary beyond normal good hygiene
practices. See Section 8 for additional personal protection
advice when handling this product.
STORAGE: Keep containers closed when not in use. Do not store in open
or unlabelled containers. Store away from strong oxidizing
agents and combustible materials. Do not store near heat,
sparks, flame or strong oxidants.
SPECIAL PRECAUTIONS: Prevent small spills and leakages to avoid slip
hazard.
EMPTY CONTAINER WARNING: Empty containers retain residue (liquid and/
or vapour) and can be dangerous. DO NOT PRESSURIZE, CUT, WELD
BRAZE, SOLDER,DRILL,GRIND OR EXPOSE SUCH CONTAINERS TO HEAT,
FLAME, SPARKS, STATIC ELECTRICITY OR OTHER SOURCES OF IGNITION;
THEY MAY EXPLODE AND CAUSE INJURY OR DEATH. Do not attempt to
refill or clean container since residue is difficult to remove.
Empty drums should be completely drained, properly bunged and
returned to a drum reconditioner. All containers should be
disposed of in an environmentally safe manner and in accordance
with governmental regulations.
--------------------------------------------------------------------------
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
--------------------------------------------------------------------------
OCCUPATIONAL EXPOSURE LIMITS:
This product does not contain any components which have recognized
exposure limits.
VENTILATION: Use adequate ventilation.

RESPIRATORY PROTECTION: No special requirements under ordinary
conditions of use and with adequate ventilation.
EYE PROTECTION: Generally eye contact is unlikely with this type
material. If eye contact is likely, safety glasses with side
shields or chemical type goggles should be worn.
SKIN PROTECTION: If prolonged or repeated skin contact is likely, oil
impervious gloves MUST be worn. Good personal hygiene practices
should always be followed.

X38 Cone Crusher
ENVIRONMENTAL CONTROLS: SEE SECTION 7
--------------------------------------------------------------------------
9. PHYSICAL AND CHEMICAL PROPERTIES
--------------------------------------------------------------------------
Typical physical properties are given below. Consult Product Data
Sheet for specific details.
GENERAL:
PHYSICAL STATE: Grease
COLOUR: Green
ODOUR: Mild
ODOUR THRESHOLD-ppm: NE
IMPORTANT HEALTH, SAFETY AND ENVIRONMENTAL INFORMATION:

pH: NA
BOILING POINT C(F): NE
FLASH POINT C(F): > 204(400) (ESTIMATED FOR OIL, ASTM D-92 (COC))
FLAMMABILITY (solids): NE
AUTO FLAMMABILITY C(F): NA
EXPLOSIVE PROPERTIES: NA
OXIDIZING PROPERTIES: NA
VAPOUR PRESSURE-mmHg 20 C: < 0.1
RELATIVE DENSITY, 15/4 C: 0.93
SOLUBILITY IN WATER: Negligible
PARTITION COEFFICIENT: > 3.5
VISCOSITY AT 40 C, cSt: 150.0
VISCOSITY AT 100 C, cSt: 13.0
VAPOUR DENSITY: NE
EVAPORATION RATE: NE
OTHER INFORMATION:
DROP POINT C(F): > 219(426)
POUR POINT C(F): NA
FREEZING POINT C(F): NE
NOTE: MOST PHYSICAL PROPERTIES FOR OIL COMPONENT.
DMSO EXTRACT, IP-346 (WT.%): <3, for mineral oil only
NA=NOT APPLICABLE NE=NOT ESTABLISHED D=DECOMPOSES
FOR FURTHER TECHNICAL INFORMATION, CONTACT YOUR MARKETING

REPRESENTATIVE
--------------------------------------------------------------------------
10. STABILITY AND REACTIVITY
--------------------------------------------------------------------------
STABILITY (THERMAL, LIGHT, ETC.): Stable.
CONDITIONS TO AVOID: Extreme heat and high energy sources of ignition.
INCOMPATIBILITY (MATERIALS TO AVOID): Strong oxidisers.
HAZARDOUS DECOMPOSITION PRODUCTS: Product does not decompose at
ambient temperatures.
HAZARDOUS POLYMERISATION: Will not occur.
--------------------------------------------------------------------------
11. TOXICOLOGICAL DATA
--------------------------------------------------------------------------
---ACUTE TOXICOLOGY---
ORAL TOXICITY: Practically non-toxic (LD50: greater than 2000
mg/kg). ---Based on testing of similar products and/or the
components.
DERMAL TOXICITY: Practically non-toxic (LD50: greater than 2000
mg/kg). ---Based on testing of similar products and/or the

X38 Cone Crusher
components.
INHALATION TOXICITY: Practically non-toxic (LC50: greater than 5
mg/l). ---Based on testing of similar products and/or the
components.
EYE IRRITATION: Practically non-irritating. (Draize score: greater
than 6 but 15 or less). ---Based on testing of similar products
and/or the components.
SKIN IRRITATION: Practically non-irritating. (Primary Irritation
Index: greater than 0.5 but less than 3). ---Based on testing
of similar products and/or the components.
OTHER ACUTE TOXICITY DATA: Although an acute inhalation study was not
performed with this product, a variety of mineral oils and
synthetic base oils, such as those in this product have been
tested. These samples had virtually no effect other than a
nonspecific inflammatory response in the lung to the aerosolized
mineral oil. The presence of additives in other tested
formulations (in approximately the same amounts as in the present
formulation) did not alter the observed effects.
---SUBCHRONIC TOXICOLOGY (SUMMARY)---

No significant adverse effects were found in studies using repeated
dermal applications of similar formulations to the skin of
laboratory animals for 13 weeks at doses significantly higher
than those expected during normal industrial exposure. The
animals were evaluated extensively for effects of exposure
(hematology, serum chemistry, urinalysis, organ weights,
microscopic examination of tissues etc.).
---REPRODUCTIVE TOXICOLOGY (SUMMARY)---

No teratogenic effects would be expected from dermal exposure, based
on laboratory developmental toxicity studies of major components
in this formulation and/or materials of similar composition.
---CHRONIC TOXICOLOGY (SUMMARY)---

Repeated and/or prolonged exposure may cause irritation to the skin,
eyes or respiratory tract. For mineral base oils: Base oils in
this product are severely solvent refined and/or severely
hydrotreated. Chronic mouse skin painting studies of severely
treated oils showed no evidence of carcinogenic effects. These
results are confirmed on a continuing basis using various
screening methods such as Modified Ames Test, IP-346, and/or
other analytical methods. Synthetic base oils representative of
those in this producthave been tested in the Ames assay and other
tests of mutagenicity with negative results. These base oils are
not expected to be carcinogenic with chronic dermal exposures.
---SENSITIZATION (SUMMARY)---
Not expected to be sensitizing based on tests of this product,
components, or similar products.
--------------------------------------------------------------------------
12. ECOLOGICAL INFORMATION
--------------------------------------------------------------------------
ENVIRONMENTAL FATE AND EFFECTS:
This environmental assessment was conducted using information on the

individual components as no test data was available for this
specific formulation.
ECOTOXICITY: This product is expected to be harmful to aquatic

X38 Cone Crusher
organisms. May cause long-term adverse effects in the aquatic

environment.
MOBILITY: Not established.
PERSISTENCE AND DEGRADABILITY: This product is expected to be

inherently biodegradable, as the principal components have been
shown to degrade at slow to moderate rates.
BIOACCUMULATIVE POTENTIAL: Not established.
--------------------------------------------------------------------------
13. DISPOSAL CONSIDERATIONS
--------------------------------------------------------------------------
WASTE DISPOSAL: Product is suitable for burning in an enclosed,
controlled burner for fuel value. Such burning may be limited
pursuant to the Resource Conservation and Recovery Act. In
addition, the product is suitable for processing by an approved
recycling facility or can be disposed of at any licensed waste
disposal site. Use of these methods is subject to user
compliance with applicable laws and regulations and consideration
of product characteristics at time of disposal.
--------------------------------------------------------------------------
14. TRANSPORT INFORMATION
--------------------------------------------------------------------------
USA DOT: NOT REGULATED BY USA DOT.
RID/ADR: NOT REGULATED BY RID/ADR.
IMO: NOT REGULATED BY IMO.
IATA: NOT REGULATED BY IATA.
--------------------------------------------------------------------------
15. REGULATORY INFORMATION
--------------------------------------------------------------------------
EU Labelling: Product is dangerous as defined by the European Union
Dangerous Substances/Preparations Directives.
Symbol: Not applicable.
Risk Phrase(s): R52/53.

Harmful to aquatic organisms, may cause long-term adverse effects
in the aquatic environment.
Safety Phrase(s): S61.

Avoid release to the environment. Refer to special
instructions/Safety data sheets.
THE FOLLOWING PRODUCT INGREDIENTS ARE CITED ON THE LISTS BELOW:
CHEMICAL NAME CAS NUMBER LIST CITATIONS

*** NO REPORTABLE INGREDIENTS ***
--- REGULATORY LISTS SEARCHED ---

1=IARC 1 6=NO ALLERGI 11=DE TERAT B 16=DE CARC B 21=CH CARC
2=IARC 2A 7=SE ALLERGY 12=DE TERAT C 17=AT TERAT A
3=IARC 2B 8=SE CARC 13=DE TERAT D 18=AT TERAT B

X38 Cone Crusher
4=NTP CARC 9=DK CARC 14=DE CARC A1 19=AT TERAT C

5=NTP SUS 10=DE TERAT A 15=DE CARC A2 20=AT TERAT D
CARC=CARCINOGEN; SUS=SUSPECTED CARCINOGEN; TERAT=TERATOGENIC
AT = Austria DE = Germany NO = Norway

CH = Switzerland DK = Denmark SE = Sweden
--------------------------------------------------------------------------
16. OTHER INFORMATION
--------------------------------------------------------------------------
LIBRARY OF RISK PHRASES LISTED IN SECTION 2 OF THIS DOCUMENT:
R22 Harmful if swallowed.

R34 Causes burns.
R36/38 Irritating to eyes and skin.
R50/53 Very toxic to aquatic organisms, may cause long-term
adverse effects in the aquatic environment.
NOTE: EXXONMOBIL PRODUCTS ARE NOT FORMULATED TO CONTAIN PCBS.
Health studies have shown that many hydrocarbons pose potential human
health risks which may vary from person to person. Information
provided on this MSDS reflects intended use. This product should not
be used for other applications. In any case, the following advice
should be considered:
INDUSTRIAL LABEL
Under normal conditions of intended use, this product does not pose a
risk to health. Excessive exposure may result in eye, skin or
respiratory irritation. Always observe good hygiene measures. First
Aid: Wash skin with soap and water. Flush eyes with water. If
overcome by fumes or vapor, remove to fresh air. If ingested, do not
induce vomiting. If symptoms persist seek medical assistance. Read
and understand the MSDS before using this product.
COSHH Regulations: Product reviewed and considered to be potentially

hazardous to health. The Regulations must be followed and
measures to control exposure may be necessary.
Any sections of this Material Safety Data Sheet which are printed in
bold text highlights recent significant changes which have been made
to the advice or information given.
**********************************************************************
For Internal Use Only: MHC: 1* 1* 1* 1* 1*, MPPEC: A, TRN:
570317-00, ELIS: 407975, CMCS97: 97Q677
EHS Approval Date: 20OCT2003
**********************************************************************
Information given herein is offered in good faith as accurate, but

without guarantee. Conditions of use and suitability of the product for
particular uses are beyond our control; all risks of use of the product
are therefore assumed by the user and WE EXPRESSLY DISCLAIM ALL
WARRANTIES OF EVERY KIND AND NATURE, INCLUDING WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN RESPECT TO THE
USE OR SUITABILITY OF THE PRODUCT. Nothing is intended as a

X38 Cone Crusher
recommendation for uses which infringe valid patents or as extending

license under valid patents. Appropriate warnings and safe handling
procedures should be provided to handlers and users. Alteration of this
document is strictly prohibited. Except to the extent required by law,
republication or retransmission of this document, in whole or in part, is
not permitted. Exxon Mobil Corporation and its affiliated companies
assume no responsibility for accuracy of information unless the document
is the most current available from an official ExxonMobil distribution
system. Exxon Mobil Corporation and its affiliated companies neither
represent nor warrant that the format, content or product formulas
contained in this document comply with the laws of any other country
except the United States of America.
Copyright 2001 Exxon Mobil Corporation, All rights reserved

X38 Cone Crusher
Safety Data Sheet
Shell Albida Grease EP 2

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY/UNDERTAKING
Product Code 001A0091

Infosafe No. ACIYK GB/eng/C
Issued Date 19/03/2005
Product Type/Use Automotive and industrial grease.
Other Names Name Code

Shell Albida Grease EP 2 140000006899
Supplier Telephone Numbers

SHELL UK PRODUCTS LTD Emergency Tel.
Stanlow Manufacturing Complex 0151-350-4595
PO Box 3
Ellesmere Port CH65 4HB Telephone/Fax Number
Technical Contact: Product HSE Depart- Tel: 0151-350-4000
ment
United Kingdom
Preparation Description
A lubricating grease containing highly-refined mineral oils and additives. The highly refined mineral oil contains
<3% (w/w) DMSO-extract, according to IP346.
Dangerous Components / Constituents
Exposure limits apply to the following components: Highly refined mineral oil.
Name CAS EINECS Proportion

Zinc naphthenate 12001-85-3 234-409-2 1-2.4 %
Other Information
See Section 16 'Other Information' for full text of each relevant Risk Phrase.
EC Classification Not classified as Dangerous under EC criteria.

Human Health Hazards
No specific hazards under normal use conditions. Prolonged or repeated exposure to skin may give rise to

X38 Cone Crusher
dermatitis. Used grease may contain harmful impurities.

Safety Hazards
Not classified as flammable, but will burn.
Symptoms and Effects

Not expected to give rise to an acute hazard under normal conditions of use.
Inhalation
In the unlikely event of dizziness or nausea, remove casualty to fresh air. If symptoms persist, obtain medical at-
tention.
Skin
Remove contaminated clothing and wash affected skin with soap and water. If persistent irritation occurs, obtain
medical attention. When using high pressure equipment, injection of product under the skin can occur. If high
pressure injuries occur, the casualty should be sent immediately to a hospital. Do not wait for symptoms to de-
velop.
Eye
Flush eye with copious quantities of water. If persistent irritation occurs, obtain medical attention.
Ingestion
Wash out mouth with water and obtain medical attention. Do not induce vomiting.
Advice to Doctor
Treat symptomatically. Aspiration into the lungs may result in chemical pneumonitis. Dermatitis may result from
prolonged or repeated exposure. High pressure injection injuries require prompt surgical intervention and pos-
sibly steroid therapy, to minimise tissue damage and loss of function.
High pressure injection injuries require surgical intervention and possibly steroid therapy to minimise tissue
damage and loss of function. Because entry wounds are small and do not reflect the seriousness of the underly-
ing damage, surgical exploration to determine the extent of involvement may be necessary. Local anaesthetics
or hot soaks should be avoided because they can contribute to swelling, vasospasm and ischaemia. Prompt
surgical decompression, debridement and evacuation of foreign material should be performed under general an-
aesthetics, and wide exploration is essential.
There may be a risk to health where low viscosity products are aspirated into the lungs following vomiting, al-
though this is uncommon in adults. Such aspiration would cause intense local irritation and chemical pneumonit-
is. Children, and those in whom consciousness is impaired, will be more at risk. Emesis of lubricants is not usu-
ally necessary, unless a large amount has been ingested, or some other compound has been dissolved in the
product. If this is indicated, for example, when there is rapid onset of central nervous system depression from
large ingested volume - gastric lavage under controlled hospital conditions, with full protection of the airway is
required. Supportive care may include oxygen, arterial blood gas monitoring, respiratory support, and, if aspira-
tion has occurred, treatment with corticosteriods and antibiotics. Seizures should be controlled with Diazepam,
or appropriate equivalent drug.
5. FIRE FIGHTING MEASURES
Specific Hazards
Combustion is likely to give rise to a complex mixture of airborne solid and liquid particulates and gases, includ-
ing carbon monoxide and unidentified organic and inorganic compounds.
Extinguishing Media
Foam and dry chemical powder. Carbon dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing Media
Water in jet. Use of halon extinguishers should be avoided for environmental reasons.

X38 Cone Crusher
Protective Equipment
Proper protective equipment including breathing apparatus must be worn when approaching a fire in a confined
space.
Personal Precautions
Avoid contact with skin and eyes. Wear PVC, Neoprene or nitrile rubber gloves. Wear rubber knee length safety
boots and PVC Jacket and Trousers. Wear safety glasses or full face shield if splashes are likely to occur.
Environmental Precautions
Prevent from spreading or entering into drains, ditches or rivers by using sand, earth, or other appropriate barri-
ers. Inform local authorities if this cannot be prevented.
Clean-up Methods - Small Spillages
Dispose into a suitable, clearly marked container for disposal or reclamation in accordance with local regula-
tions.
Clean-up Methods - Large Spillages
As for small spills.
Handling
Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Avoid prolonged or re-
peated contact with skin. When handling product in drums, safety footwear should be worn and proper handling
equipment should be used. Prevent spillages. Cloth, paper and other materials that are used to absorb spills
present a fire hazard. Avoid their accumulation by disposing of them safely and immediately. In addition to any
specific recommendations given for controls of risks to health, safety and the environment, an assessment of
risks must be made to help determine controls appropriate to local circumstances. Exposure to this product
should be reduced as low as reasonably practicable. Reference should be made to the Health and Safety Exec-
utive's publication 'COSHH Essentials'.
Storage
Keep in a cool, dry, well-ventilated place. Use properly labelled and closeable containers. Avoid direct sunlight,
heat sources, and strong oxidizing agents. The storage of this product maybe subject to the Control of Pollution
(Oil Storage) (England) Regulations. Further guidance maybe obtained from the local environmental agency of-
fice.
Storage Temperatures
0ºC Minimum. 50ºC Maximum.
Recommended Materials
For containers or container linings, use mild steel or high density polyethylene.
Unsuitable Materials
For containers or container linings, avoid PVC.
Other Information
Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion.
8. EXPOSURE CONTROLS, PERSONAL PROTECTION
Exposure Limits

X38 Cone Crusher
Substance Regulations Exposure Dura- Exposure Limit Units Notes

tion
Health and Safety Exec-
Oil mist, mineral utive. EH40; Occupa- TWA 5 mg/m3
tional Exposure Limits.
Health and Safety Exec-
utive. EH40; Occupa- STEL 10 mg/m3
tional Exposure Limits.
Other Exposure Information
Due to the product's semi-solid consistency, generation of mists and dusts is unlikely to occur.
Exposure Controls
The use of personal protective equipment is only one aspect of an integrated approach to the Control Of Sub-
stances Hazardous to Health.
The management of Health and Safety at Work Regulations 1992 require employers to identify and evaluate the
risks to health and to implement appropriate measures to eliminate or minimise those risks. The choice of per-
sonal protective equipment is highly dependent upon local conditions, e.g. exposure to other chemical sub-
stances and micro-organisms, thermal hazards (protection from extremes of cold and heat), electrical hazards,
mechanical hazards and appropriate degree of manual dexterity required to undertake an activity.
Whilst the content of this section may inform the choice of personal protective equipment used, the limitations of
any information which can be provided must be fully understood, e.g. personal protective equipment chosen to
protect employees from occasional splashes maybe entirely inadequate for activities involving partial or com-
plete immersion.If the levels of oil mist or vapour in air are likely to exceed the occupational exposure standards
then consideration should be given to the use of local exhaust ventilation to reduce personal exposure.
The choice of personal protective equipment should only be undertaken in the light of a full risk assessment by
a suitably qualified competent person ( e.g. a professionally qualified occupational hygienist).
Effective protection is only achieved by correctly fitting and well maintained equipment and employers should
ensure that appropriate training is given. All personal protective equipment should be regularly inspected and
replaced if defective. Reference should be made to HSE's publication Methods for the Determination of Hazard-
ous Substances (MDHS) 84 - Measurement of oil mist from mineral oil-based metalworking fluids. Measurement
of an employee's exposure to oil vapour maybe supplemented through the use of stain tubes. In the first in-
stance, further guidance maybe obtained through HSE's publication 'COSHH - a brief guide to the regulations'
(INDG 136(rev1)).
Respiratory Protection
At standard temperature and pressure, the Occupational Exposure Standard for oil vapour is unlikely to be ex-
ceeded. Care should be taken to keep exposures below applicable occupational exposure limits. If this cannot
be achieved, use of a respirator fitted with an organic vapour cartridge combined with a particulate pre-filter
should be considered. Half masks (EN 149) or valved half masks (EN 405) in combination with type A2 (EN
141) and P2/3 (EN 143) pre-filters maybe considered.
If product is subjected to elevated temperatures, half masks (EN 149) or valved half masks (EN 405) in combin-
ation with type AX (EN 371) and P2/3 (EN 143) prefilters maybe considered.
Hand Protection
Chemical protective gloves are made from a wide range of materials, but there is no single glove material ( or
combination of materials) which gives unlimited resistance to any individual or combination of substances or
preparations. The extent of the breakthrough time will be affected by a combination of factors which include per-
meation, penetration, degradation, use pattern ( full immersion, occasional contacts) and how the glove is
stored when not in use.
Theoretical maximum levels of protection are seldom achieved in practice and the actual level of protection can
be difficult to assess. Effective breakthrough time should be used with care and a margin of safety should be ap-
plied. HSE guidance on protective gloves recommends a 75% safety factor to be applied to any figures obtained
in a laboratory test. Nitrile gloves may offer relatively long breakthrough times and slow permeation rates. Test
data, e.g breakthrough data obtained through test standard EN374-3:1994 are available from reputable equip-
ment suppliers.
Personal hygiene is a key element of effective hand care. Gloves must only be worn on clean hands. After using

X38 Cone Crusher
gloves, hands should be washed and dried thoroughly. A non perfumed moisturiser should be applied.
Eye Protection
Goggles conforming to a minimum standard of EN 166 345B should be considered if there is a possibility of eye
contact with the product through splashing. Higher rated eye protection must be considered for highly hazard-
ous operations or work areas. For example, employees involved in metalworking operations such as chipping,
grinding or cutting may require additional protection to avert injury from fast moving particles or broken tools.
Body Protection
Minimise all forms of skin contact. Overalls and shoes with oil resistant soles should be worn. Launder overalls
and undergarments regularly.
Environmental Exposure Controls
Minimise release to the environment. An environmental assessment must be made to ensure compliance with
local environmental legislation.
Colour Light brown.

Physical State Semi-solid at ambient temperature.
Odour Characteristic mineral oil.
pH Value Data not available.
Vapour Pressure Expected to be less than 0.5 Pa at 20°C.
Initial Boiling Point Data not available.
Solubility in Water Negligible.
Density circa 900 kg/m3 at 15ºC.
Flash Point >250ºC (COC) (based on mineral oil).
Flammable Limits - Upper 10% V/V (typical) (based on mineral oil).
Flammable Limits - Lower 1% V/V (typical) (based on mineral oil).
Auto-Ignition Temperature Expected to be above 320ºC.
Kinematic Viscosity Data not available.
Vapour Density (Air=1) Greater than 1.
Partition co-efficient, n-octanol/water Log Pow expected to be greater than 6.
Dropping Point >250ºC (ASTM D-566).
Stability
Stable.
Conditions to Avoid
Extremes of temperature and direct sunlight.
Materials to Avoid
Strong oxidizing agents.
Hazardous Decomposition Products
Hazardous decomposition products are not expected to form during normal storage.
11. TOXICOLOGICAL INFORMATION

X38 Cone Crusher
Basis for Assessment

Toxicological data have not been determined specifically for this product. Information given is based on a know-
ledge of the components and the toxicology of similar products.
Acute Toxicity - Oral
LD50 expected to be > 2000 mg/kg.
Acute Toxicity - Dermal
Acute Toxicity - Inhalation
Not considered to be an inhalation hazard under normal conditions of use.
Eye Irritation
Expected to be slightly irritating.
Skin Irritation
Respiratory Irritation
If vapours are inhaled, slight irritation of the respiratory tract may occur.
Skin Sensitisation
Not expected to be a skin sensitizer.
Carcinogenicity
Product is based on mineral oils of types shown to be non-carcinogenic in animal skin-painting studies. Other
components are not known to be associated with carcinogenic effects.
Mutagenicity
Not considered to be a mutagenic hazard.
Reproductive Toxicity
Not considered to be toxic to reproduction.
Other Information
Prolonged and/or repeated contact with products containing mineral oils can result in defatting of the skin, par-
ticularly at elevated temperatures. This can lead to irritation and possibly dermatitis, especially under conditions
of poor personal hygiene. Skin contact should be minimised. High pressure injection of product into the skin
may lead to local necrosis if the product is not surgically removed. Used grease may contain harmful impurities
that have accumulated during use.The concentration of such harmful impurities will depend on use and they
may present risks to health and the environment on disposal. ALL used grease should be handled with caution
and skin contact avoided as far as possible.

Ecotoxicological data have not been determined specifically for this product. Information given is based on a
knowledge of the components and the ecotoxicology of similar products.
Mobility
Semi-solid under most environmental conditions. Floats on water. If it comes into contact with soil, it will strongly
adsorb to soil particles.
Persistence / Degradability
Not expected to be readily biodegradable. Major constituents are expected to be inherently biodegradable, but
the product contains components that may persist in the environment.
Bioaccumulation
Contains components with the potential to bioaccumulate.

X38 Cone Crusher
Ecotoxicity
Data not available. Poorly soluble mixture. May cause physical fouling of aquatic organisms.
Other Adverse Effects
Not expected to have ozone depletion potential, photochemical ozone creation potential or global warming po-
tential.
Product is a mixture of non-volatile components, which are not expected to be released to air in any significant
quantities.
Waste Disposal
Dispose into a suitable, clearly marked container for disposal or reclamation in accordance with local regula-
tions. The competence of the contractor to deal satisfactorily with this type of product should be established be-
forehand. Do not pollute the soil, water or environment with the waste product.
Product Disposal
As for waste disposal.
Container Disposal
Recycle or dispose of in accordance with the legislation in force with a recognised collector or contractor.
Transport Information
Not dangerous for transport under ADR/RID, IMO and IATA/ICAO regulations.
EC Symbols None.
EC Risk Phrase Not classified.
EC Safety Phrase Not classified.
EINECS All components listed or polymer exempt.
TSCA (USA) All components listed.

National Legislation
Environmental Protection Act 1990 (as amended).
Health and Safety at Work Act 1974
Consumers Protection Act 1987
Control of Pollution Act 1974
Environmental Act 1995
Factories Act 1961
Carriage of Dangerous Goods by Road and Rail (Classification, Packaging and Labelling) Regulations
Chemicals (Hazard Information and Packaging for Supply) Regulations 2002.
Control of Substances Hazardous to Health Regulations 1994 (as amended).
Road Traffic (Carriage of Dangerous Substances in Packages) Regulations
Merchant Shipping (Dangerous Goods and Marine Pollutants) Regulations
Road Traffic (Carriage of Dangerous Substances in Road Tankers in Tank Containers) Regulations
Road Traffic (Training of Drivers of Vehicles Carrying Dangerous Goods) Regulations

X38 Cone Crusher
Reporting of Injuries, Diseases and Dangerous Occurences Regulations

Health and Safety (First Aid) Regulations 1981
Personal Protective Equipment (EC Directive) Regulations 1992
Personal Protective Equipment at Work Regulations 1992
Packaging & Labelling
Safety data sheet available for professional user on request.
Revisions Highlighted
To assist harmonisation of sds authoring practices, a version number has been introduced.
References
GUIDANCE NOTES
UK Chemicals Regulatory Atlas, An Overview of how to guide your chemical through to regulatory compliance
(DTI).
HSG71 The storage of packaged dangerous substances.
EH/40 Occupational Exposure Limits.
EH/58 The Carcinogenicity of Mineral Oils.
MS24 Health surveillance of occupational skin disease.
HSG 53 The selection, use and maintenance of respiratory protective equipment: A practical guide.
HSG 206 Cost and effectiveness of chemical protective gloves for the workplace: Guidance for employers and
health and safety specialists.
L74 First Aid at work: Approved Code of Practice and Guidance.
HSG 136 Workplace transport safety : guidance for employers.
INDG234 (rev) Are you Involved in the Carriage of Dangerous Goods by Road or Rail
OTHER LITERATURE
Concawe Report 3/82 Precautionary Advice on the Handling of Used Engine Oils
Concawe Report 86/69 Health Aspects of Worker Exposure to Oil Mists
Concawe Report 01/97 Petroleum Products - First Aid Emergency and Medical Advice
Concawe Report 01/53 Classification and labelling of petroleum substances according to the EU dangerous
substances directive ( Concawe recommendations August 2001)
Concawe Report 01/54 environmental classification of petroleum substances summary data and rationale
Concawe Report 5/02 amended safety data sheet directive ( 2001/58/EC)
Department of the Environment - Waste Management - The Duty of Care - A Code of Practice
Concawe, Boulevard du souverain 165 B - 1160 Brussels, Belgium
www.concawe.be
Restrictions
This product must not be used in applications other than recommended without first seeking the advice of the
SHELL technical department.
List of R Phrases in Section 2
R36/38 Irritating to eyes and skin.
R51/53 Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
Technical Contact Numbers
0151-350-4000.
Further Information
This information is based on our current knowledge and is intended to describe the product for the purposes of
health, safety and environmental requirements only. It does not constitute a guarantee for any specific property
of the product.
... End Of SDS ...

X38 Cone Crusher

X38 Cone Crusher
Safety Data Sheet
Shell Rimula Signia 10W 40

Product Code 001B1657

Infosafe No. ACLI2 IT/eng/C
Product Type/Use Engine oil.

Shell Rimula Signia 10W 40 140001485394
Emergency Tel.
Shell Italia S.p.A (+39) 02 3800.4461/2 (attivo 24 ore su 24).
Via. A. Manzoni, 44 Telephone/Fax Number
20095 Cusano Milanino (Mi) Tel: (+39) 02 6110.1 (Operator, office hours) (+39) 031 360283 (MSDS
ITALY focal point, office hours) Fax: (+39) 02 6110.3411
Highly refined mineral oil, severely hydrotreated slack wax and additives. The highly refined mineral oil con-
tains <3% (w/w) DMSO-extract, according to IP346. The highly refined mineral oil is only present as additive
diluent.
Name CAS EINECS Proportion Hazard R Phrase

Calcium long chain
- - 1-2.49 % R52/53
alkyl salicylate
Alkyl phenol - - 0.1-1.49 % R53
Other Information
See Section 16 'Other Information' for full text of each relevant Risk Phrase.

No specific hazards under normal use conditions. Prolonged or repeated exposure to skin may give rise to
dermatitis. Used oil may contain harmful impurities.

X38 Cone Crusher
Safety Hazards
Environmental Hazards
Not classified as dangerous for the environment.

Inhalation
In the unlikely event of dizziness or nausea, remove casualty to fresh air. If symptoms persist, obtain medical
attention.
Skin
Remove contaminated clothing and wash affected skin with soap and water. If persistent irritation occurs, ob-
tain medical attention. When using high pressure equipment, injection of product under the skin can occur. If
high pressure injuries occur, the casualty should be sent immediately to a hospital. Do not wait for symptoms
to develop.
Eye
Ingestion
Advice to Doctor
Treat symptomatically. Aspiration into the lungs may result in chemical pneumonitis. Dermatitis may result
from prolonged or repeated exposure. High pressure injection injuries require prompt surgical intervention
and possibly steroid therapy, to minimise tissue damage and loss of function.
Specific Hazards
Combustion is likely to give rise to a complex mixture of airborne solid and liquid particulates and gases, in-
cluding carbon monoxide and unidentified organic and inorganic compounds.
Extinguishing Media
Proper protective equipment including breathing apparatus must be worn when approaching a fire in a con-
fined space.
Avoid contact with skin and eyes. Wear PVC, Neoprene or nitrile rubber gloves. Wear rubber knee length
safety boots and PVC Jacket and Trousers. Wear safety glasses or full face shield if splashes are likely to oc-
cur.
Prevent from spreading or entering into drains, ditches or rivers by using sand, earth, or other appropriate
barriers. Inform local authorities if this cannot be prevented.

X38 Cone Crusher

Absorb liquid with sand or earth. Sweep up and remove to a suitable, clearly marked container for disposal in
accordance with local regulations.
Prevent from spreading by making a barrier with sand, earth or other containment material. Reclaim liquid dir-
ectly or in an absorbent. Dispose of as for small spills.
Handling
Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Avoid prolonged or re-
peated contact with skin. When handling product in drums, safety footwear should be worn and proper hand-
ling equipment should be used. Prevent spillages. Cloth, paper and other materials that are used to absorb
spills present a fire hazard. Avoid their accumulation by disposing of them safely and immediately. In addition
to any specific recommendations given for controls of risks to health, safety and the environment, an assess-
ment of risks must be made to help determine controls appropriate to local circumstances.
Storage
Keep in a cool, dry, well-ventilated place. Use properly labelled and closeable containers. Avoid direct sun-
light, heat sources, and strong oxidizing agents.
Other Information
Exposure Limits
Exposure Dura-
Substance Regulations Exposure Limit Units Notes
tion
Oil mist, mineral ACGIH TWA 5 mg/m3
ACGIH STEL 10 mg/m3
ACGIH ACGIH Threshold Limit Values.

Exposure Controls
The choice of personal protective equipment is highly dependent upon local conditions, e.g. exposure to other
chemical substances and micro-organisms, thermal hazards (protection from extremes of cold and heat),
electrical hazards, mechanical hazards and appropriate degree of manual dexterity required to undertake an
activity.
Whilst the content of this section may inform the choice of personal protective equipment used, the limitations
of any information which can be provided must be fully understood, e.g. personal protective equipment
chosen to protect employees from occasional splashes maybe entirely inadequate for activities involving par-
tial or complete immersion.If the levels of oil mist or vapour in air are likely to exceed the occupational expos-
ure standards then consideration should be given to the use of local exhaust ventilation to reduce personal
exposure.
The choice of personal protective equipment should only be undertaken in the light of a full risk assessment
by a suitably qualified competent person ( e.g. a professionally qualified occupational hygienist).

X38 Cone Crusher
replaced if defective.
At standard temperature and pressure, the Occupational Exposure Standard for oil vapour is unlikely to be
exceeded. Care should be taken to keep exposures below applicable occupational exposure limits. If this
cannot be achieved, use of a respirator fitted with an organic vapour cartridge combined with a particulate
pre-filter should be considered. Half masks (EN 149) or valved half masks (EN 405) in combination with type
A2 (EN 141) and P2/3 (EN 143) pre-filters maybe considered.
Hand Protection
Nitrile gloves may offer relatively long breakthrough times and slow permeation rates. Test data, e.g break-
through data obtained through test standard EN374-3:1994 are available from reputable equipment suppliers.
Personal hygiene is a key element of effective hand care. Gloves must only be worn on clean hands. After
using gloves, hands should be washed and dried thoroughly. A non perfumed moisturiser should be applied.
preparations. The extent of the breakthrough time will be affected by a combination of factors which include
permeation, penetration, degradation, use pattern ( full immersion, occasional contacts) and how the glove is
Theoretical maximum levels of protection are seldom achieved in practice and the actual level of protection
can be difficult to assess.
Eye Protection
Goggles conforming to a minimum standard of EN 166 345B should be considered if there is a possibility of
eye contact with the product through splashing. Higher rated eye protection must be considered for highly
hazardous operations or work areas. For example, employees involved in metalworking operations such as
chipping, grinding or cutting may require additional protection to avert injury from fast moving particles or
broken tools.
Body Protection
Minimise all forms of skin contact. Overalls and shoes with oil resistant soles should be worn. Launder over-
alls and undergarments regularly.

Colour Amber.
Physical State Liquid at ambient temperature.
Initial Boiling Point Expected to be above 280°C.
Density 850 kg/m3 at 15ºC.
Flash Point 251ºC (COC).
Flammable Limits - Upper 10%(V/V) (estimated value).
Flammable Limits - Lower 1%(V/V) (estimated value).
Kinematic Viscosity 82 mm2/s at 40ºC.
Evaporation Rate Data not available.
Partition co-efficient, n-octanol/water Log Pow >6 (typical).

X38 Cone Crusher
Pour Point -36ºC.
Stability
Stable.
Conditions to Avoid
Materials to Avoid

Toxicological data have not been determined specifically for this product. Information given is based on a
knowledge of the components and the toxicology of similar products.
Eye Irritation
Skin Irritation
If mists are inhaled, slight irritation of the respiratory tract may occur.
Skin Sensitisation
Carcinogenicity
Components are not known to be associated with carcinogenic effects.
Mutagenicity
Other Information
Prolonged and/or repeated contact with this product can result in defatting of the skin, particularly at elevated
temperatures. This can lead to irritation and possibly dermatitis, especially under conditions of poor personal
hygiene. Skin contact should be minimised. High pressure injection of product into the skin may lead to local
necrosis if the product is not surgically removed. Used oils may contain harmful impurities that have accumu-
lated during use. The concentration of such impurities will depend on use and they may present risks to
health and the environment on disposal. ALL used oil should be handled with caution and skin contact
avoided as far as possible.

X38 Cone Crusher

Mobility
Liquid under most environmental conditions. Floats on water. If it enters soil, it will adsorb to soil particles and
will not be mobile.
Not expected to be readily biodegradable. Major constituents are expected to be inherently biodegradable,
but the product contains components that may persist in the environment.
Bioaccumulation
Ecotoxicity
Poorly soluble mixture. May cause physical fouling of aquatic organisms. Product is expected to be practically
non-toxic to aquatic organisms, LL/EL50 >100 mg/l. (LL/EL50 expressed as the nominal amount of product
required to prepare aqueous test extract).
Not expected to have ozone depletion potential, photochemical ozone creation potential or global warming
potential.
Product is a mixture of non-volatile components, which are not expected to be released to air in any signific-
ant quantities.
Waste Disposal
Recycle or dispose of in accordance with prevailing regulations, by a recognised collector or contractor. The
competence of the contractor to deal satisfactorily with this type of product should be established beforehand.
Do not pollute the soil, water or environment with the waste product.
Product Disposal
Container Disposal
EU Waste Disposal Code (EWC)
13 02 06 synthetic engine, gear and lubricating oils.
Classification of waste is always the responsibility of the end user.
National, state, local regulations
Il prodotto esausto è classificato rifiuto speciale pericoloso (ai sensi dell'art. 1, par. 4 della Direttiva
91/689/CEE).
Lo smaltimento e regolato dal DL 05/02/97 in attuazione alle direttive 91/156, 91/689 e 94/62.
Il CER e stato aggiornato dalla decisione 2000/532/CE, modificata successivamente dalle decisioni
2001/118/CE, 2001/119/CE e 2001/573/CE.

X38 Cone Crusher
EC Symbols None.
TSCA (USA) All components in compliance.
- classificazione, imballaggio ed etichettatura sostanze pericolose. (D.Lgs. 52/1997 e succ. mod.).
- classificazione, imballaggio ed etichettatura preparati pericolosi. (D.Lgs. 65/2003).
- modalità di informazione su sostanze e preparati pericolosi (DM 07/09/2002 e succ. mod.).
- norme generali per l'igiene del lavoro (D.P.R. n. 303 del 19/03/1956).
- igiene del lavoro - Dispositivi di Protezione Individuale (DPI) (D.Lgs. 475 - 04/12/1992 e succ. agg.).
- tabella delle malattie professionali nell'industria (D.P.R. 336 - 13/04/1994).
- decreto sulla sicurezza sul lavoro (D.Lgs. 626/1994 e succ. mod.).
- oli usati (D.Lgs. 95/1992 e succ. mod.).
- D.Lgs. 334 - 17/8/99 e succ. mod. (Seveso II).
- ammine aromatiche (Circ. Min. 46/1979 e 61/1961).
- restrizioni per l'immissione sul mercato e uso di talune sostanze e preparati pericolosi (D.P.R. 904 -
10/09/1982 e succ. agg.).
Because of a new system the version number was reset.
References
67/548/EEC - Dangerous Substances Directive.
1999/45/EC - Dangerous Preparations Directive.
91/155/EEC - Safety Data Sheet Directive.
98/24/EC - Protection of the Health and Safety of Workers from risks related to chemical agents at work.
89/686/EEC - Approximation of the laws of the member of states relating to personal protective equipment.
76/769/EEC - Restrictions of the marketing and use.
Relevant Comité Européen de Normalisation (CEN) standards giving specific requirements for personal pro-
tective equipment.
European Model Code of Safe Practice in the Storage and Handling of Petroleum Products
Concawe Report 01/53 - Classification and labelling of petroleum substances according to the EU dangerous
substances directive.
Concawe Report 03/82 - Precautionary Advice on the Handling of Used Engine Oils
Concawe Report 01/97 - Petroleum Products - First Aid and Emergency Advice
Concawe Report 86/89 - Health Aspects of Workers Exposure to Oil Mists
Concawe Report 01/54 - Environmental Classification of Petroleum Substances - Summary Data and Ra-
tionale
EN 374-2:1994 Protective gloves against chemicals and micro-organisms
EN 149:2001 Respiratory protective devices - filtering half masks to protect against particles - requirements,
testing, marking
EN 405:1992 Respiratory protective devices - valved filtering half masks to protect against gases or gases
and particles - requirements, testing, marking.
EN 141:2000 Respiratory protective devices - gas filters and combined filters - requirements, testing, marking
EN 143:2000 Respiratory protective devices - particle filters - requirements, testing, marking
EN 166:1995 Personal eye-protection - specification.

X38 Cone Crusher
Restrictions
List of R Phrases in Section 2
R53 May cause long term adverse effects in the aquatic environment.
R52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic environment.
(+39) 02 6110.3000.
Further Information
This information is based on our current knowledge and is intended to describe the product for the purposes
of health, safety and environmental requirements only. It does not constitute a guarantee for any specific
property of the product.
... End Of SDS ...

X38 Cone Crusher
Safety Data Sheet
Shell Tellus Oil 46

Product Code 001B0669

Infosafe No. ACKQ6 GB/eng/C
Product Type/Use Hydraulic oil.

Shell Tellus Oil 46 140001010640

Stanlow Manufacturing Complex
0151-350-4595
PO Box 3
Ellesmere Port Telephone/Fax Number
CH65 4HB Tel: 0151-350-4000
Technical Contact: Product HSE
Department
United Kingdom
Highly refined mineral oils and additives. The highly refined mineral oil contains <3% (w/w) DMSO-extract,
according to IP346.

No specific hazards under normal use conditions. Prolonged or repeated exposure may give rise to dermatitis.
Used oil may contain harmful impurities.
Safety Hazards

X38 Cone Crusher

Inhalation
attention.
Skin
medical attention. If high pressure injection injuries occur, obtain medical attention immediately.
Eye
Ingestion
Advice to Doctor
prolonged or repeated exposure.
High pressure injection injuries require surgical intervention and possibly steroid therapy to minimise tissue
damage and loss of function. Because entry wounds are small and do not reflect the seriousness of the
underlying damage, surgical exploration to determine the extent of involvement may be necessary. Local
anaesthetics or hot soaks should be avoided because they can contribute to swelling, vasospasm and
ischaemia. Prompt surgical decompression, debridement and evacuation of foreign material should be
performed under general anaesthetics, and wide exploration is essential.
There may be a risk to health where low viscosity products are aspirated into the lungs following vomiting,
although this is uncommon in adults. Such aspiration would cause intense local irritation and chemical
pneumonitis. Children, and those in whom consciousness is impaired, will be more at risk. Emesis of lubricants
is not usually necessary, unless a large amount has been ingested, or some other compound has been
dissolved in the product. If this is indicated, for example, when there is rapid onset of central nervous system
depression from large ingested volume - gastric lavage under controlled hospital conditions, with full protection
of the airway is required. Supportive care may include oxygen, arterial blood gas monitoring, respiratory
support, and, if aspiration has occurred, treatment with corticosteriods and antibiotics. Seizures should be
controlled with Diazepam, or appropriate equivalent drug.
Specific Hazards
Combustion is likely to give rise to a complex mixture of airborne solid and liquid particulates and gases,
including carbon monoxide, oxides of sulphur, and unidentified organic and inorganic compounds.
Extinguishing Media
space.

X38 Cone Crusher
Prevent from spreading by making a barrier with sand, earth or other containment material. Reclaim liquid
directly or in an absorbent. Dispose of as for small spills.
Handling
Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Avoid prolonged or
repeated contact with skin. When handling product in drums, safety footwear should be worn and proper
handling equipment should be used. Prevent spillages. Cloth, paper and other materials that are used to absorb
spills present a fire hazard. Avoid their accumulation by disposing of them safely and immediately. In addition to
any specific recommendations given for controls of risks to health, safety and the environment, an assessment
of risks must be made to help determine controls appropriate to local circumstances. Exposure to this product
should be reduced as low as reasonably practicable. Reference should be made to the Health and Safety
Executive's publication 'COSHH Essentials'.
Storage
heat sources, and strong oxidizing agents. The storage of this product maybe subject to the Control of Pollution
(Oil Storage) (England) Regulations. Further guidance maybe obtained from the local environmental agency
office.
Other Information
Exposure Limits
Substance Regulations Exposure Exposure Limit Units Notes
Duration
Health and Safety
Executive. EH40;
Oil mist, mineral TWA 5 mg/m3
Occupational Exposure
Limits.

X38 Cone Crusher
Health and Safety

Executive. EH40;
STEL 10 mg/m3
Occupational Exposure
Limits.
Exposure Controls
The use of personal protective equipment is only one aspect of an integrated approach to the Control Of
Substances Hazardous to Health.
risks to health and to implement appropriate measures to eliminate or minimise those risks. The choice of
personal protective equipment is highly dependent upon local conditions, e.g. exposure to other chemical
substances and micro-organisms, thermal hazards (protection from extremes of cold and heat), electrical
hazards, mechanical hazards and appropriate degree of manual dexterity required to undertake an activity.
protect employees from occasional splashes maybe entirely inadequate for activities involving partial or
complete immersion.If the levels of oil mist or vapour in air are likely to exceed the occupational exposure
standards then consideration should be given to the use of local exhaust ventilation to reduce personal
exposure.
replaced if defective. Reference should be made to HSE's publication Methods for the Determination of
Hazardous Substances (MDHS) 84 - Measurement of oil mist from mineral oil-based metalworking fluids.
Measurement of an employee's exposure to oil vapour maybe supplemented through the use of stain tubes. In
the first instance, further guidance maybe obtained through HSE's publication 'COSHH - a brief guide to the
regulations' (INDG 136(rev1)).
At standard temperature and pressure, the Occupational Exposure Standard for oil vapour is unlikely to be
exceeded. Care should be taken to keep exposures below applicable occupational exposure limits. If this cannot
be achieved, use of a respirator fitted with an organic vapour cartridge combined with a particulate pre-filter
should be considered. Half masks (EN 149) or valved half masks (EN 405) in combination with type A2 (EN
141) and P2/3 (EN 143) pre-filters maybe considered.
If product is subjected to elevated temperatures, half masks (EN 149) or valved half masks (EN 405) in
combination with type AX (EN 371) and P2/3 (EN 143) prefilters maybe considered.
Hand Protection
be difficult to assess. Effective breakthrough time should be used with care and a margin of safety should be
applied. HSE guidance on protective gloves recommends a 75% safety factor to be applied to any figures
obtained in a laboratory test. Nitrile gloves may offer relatively long breakthrough times and slow permeation
rates. Test data, e.g breakthrough data obtained through test standard EN374-3:1994 are available from
reputable equipment suppliers.
Eye Protection
contact with the product through splashing. Higher rated eye protection must be considered for highly
chipping, grinding or cutting may require additional protection to avert injury from fast moving particles or broken

X38 Cone Crusher
tools.
Body Protection
Colour Light brown.

pH Value Not applicable.
Density 879 kg/m3 at 15ºC.
Flash Point 218ºC. (PMCC).
Flammable Limits - Upper 10%(V/V) (typical).
Flammable Limits - Lower 1%(V/V) (typical).
Kinematic Viscosity 46 mm2/s at 40°C.
Pour Point -30ºC.
Stability
Stable.
Conditions to Avoid
Materials to Avoid


X38 Cone Crusher

Eye Irritation
Skin Irritation
Skin Sensitisation
Carcinogenicity
Product is based on mineral oils of types shown to be non-carcinogenic in animal skin-painting studies. Other
components are not known to be associated with carcinogenic effects.
Mutagenicity
Other Information
Prolonged and/or repeated contact with products containing mineral oils may result in defatting of the skin,
particularly at elevated temperatures. This may lead to irritation and possibly dermatitis, especially under
conditions of poor personal hygiene. Skin contact should be minimised. Used oils may contain harmful
impurities that have accumulated during use. The concentration of such impurities will depend on use and they
may present risks to health and the environment on disposal. ALL used oil should be handled with caution and
skin contact avoided as far as possible.

Mobility
will not be mobile.
Bioaccumulation
Ecotoxicity
required to prepare aqueous test extract). Mineral oil is not expected to cause any chronic effects to aquatic
organisms at concentrations less than 1 mg/l.

X38 Cone Crusher

potential.
quantities.
Waste Disposal
Recycle or dispose of in accordance with prevailing regulations, with a recognised collector or contractor. The
Product Disposal
Container Disposal
EC Symbols None.

Factories Act 1961

X38 Cone Crusher

No amendments made to information. To assist harmonisation of sds authoring practices, a version number has
been introduced.
References
GUIDANCE NOTES
UK Chemicals Regulatory Atlas, An Overview of how to guide your chemical through to regulatory compliance
(DTI).
HSG71 The storage of packaged dangerous substances.
EH/40 Occupational Exposure Limits.
EH/58 The Carcinogenicity of Mineral Oils.
MS24 Health surveillance of occupational skin disease.
HSG 53 The selection, use and maintenance of respiratory protective equipment: A practical guide.
HSG 206 Cost and effectiveness of chemical protective gloves for the workplace: Guidance for employers and
health and safety specialists.
L74 First Aid at work: Approved Code of Practice and Guidance.
HSG 136 Workplace transport safety : guidance for employers.
INDG234 (rev) Are you Involved in the Carriage of Dangerous Goods by Road or Rail
OTHER LITERATURE
Concawe Report 3/82 Precautionary Advice on the Handling of Used Engine Oils
Concawe Report 86/69 Health Aspects of Worker Exposure to Oil Mists
Concawe Report 01/53 Classification and labelling of petroleum substances according to the EU dangerous
substances directive ( Concawe recommendations August 2001)
Concawe Report 01/54 environmental classification of petroleum substances summary data and rationale
Concawe Report 5/02 amended safety data sheet directive ( 2001/58/EC)
Concawe, Boulevard du souverain 165 B - 1160 Brussels, Belgium
www.concawe.be
Restrictions
0151-350-4000.
Further Information
of the product.
... End Of SDS ...

X38 Cone Crusher
Safety Data Sheet
Shell Naturelle Fluid HF-M 46


Infosafe No. ACKXR GB/eng/C
Product Type/Use Hydraulic oil.

Shell Naturelle Fluid HF-M 46 140000000988

Stanlow Manufacturing Complex
0151-350-4595
PO Box 3
Ellesmere Port Telephone/Fax Number
CH65 4HB Tel: 0151-350-4000
Technical Contact: Product HSE
Department
United Kingdom
Blend of vegetable oils, esters and additives.

Safety Hazards

X38 Cone Crusher

Inhalation
attention.
Skin
Eye
Ingestion
Do not induce vomiting. Wash out mouth with water and obtain medical attention.
Advice to Doctor
High pressure injection injuries may require surgical intervention and possibly steroid therapy to minimise tissue
damage and loss of function. Because entry wounds are small and may not reflect the seriousness of the
underlying damage, surgical exploration to determine the extent of involvement may be necessary.
Emesis of lubricants is not usually necessary, unless a large amount has been ingested, or some other
compound has been dissolved in the product. If this is indicated, for example, when there is rapid onset of
central nervous system depression from large ingested volume - gastric lavage under controlled hospital
conditions, with full protection of the airway is required. Supportive care may include oxygen, arterial blood gas
monitoring, respiratory support, and, if aspiration has occurred, treatment with corticosteriods and antibiotics.
Seizures should be controlled with Diazepam, or appropriate equivalent drug.
Specific Hazards
including carbon monoxide and unidentified organic and inorganic compounds.
Extinguishing Media
space.

X38 Cone Crusher
Handling
of risks must be made to help determine controls appropriate to local circumstances. Exposure to this product
should be reduced as low as reasonably practicable. Reference should be made to the Health and Safety
Executive's publication 'COSHH Essentials'.
Storage
heat sources, and strong oxidizing agents.
Other Information
Exposure Limits
No Exposure Limit Established
Exposure Controls
The use of personal protective equipment is only one aspect of an integrated approach to the Control Of
Substances Hazardous to Health.
risks to health and to implement appropriate measures to eliminate or minimise those risks. The choice of
personal protective equipment is highly dependent upon local conditions, e.g. exposure to other chemical
substances and micro-organisms, thermal hazards (protection from extremes of cold and heat), electrical
hazards, mechanical hazards and appropriate degree of manual dexterity required to undertake an activity.
exposure.

X38 Cone Crusher
Care should be taken to keep exposures below applicable occupational exposure limits. If this cannot be
achieved, use of a respirator fitted with an organic vapour cartridge combined with a particulate pre-filter should
be considered. Half masks (EN 149) or valved half masks (EN 405) in combination with type A2 (EN 141) and
P2/3 (EN 143) pre-filters maybe considered.
If product is subjected to elevated temperatures, half masks (EN 149) or valved half masks (EN 405) in
Hand Protection
be difficult to assess. Effective breakthrough time should be used with care and a margin of safety should be
applied. HSE guidance on protective gloves recommends a 75% safety factor to be applied to any figures
obtained in a laboratory test. Nitrile gloves may offer relatively long breakthrough times and slow permeation
rates. Test data, e.g breakthrough data obtained through test standard EN374-3:1994 are available from
reputable equipment suppliers.
Eye Protection
tools.
Body Protection
Colour Red.
Odour Slight.
Flash Point 214ºC (COC).
Flammable Limits - Upper Data not available.

X38 Cone Crusher
Flammable Limits - Lower Data not available.

Auto-Ignition Temperature Data not available.
Kinematic Viscosity circa 42 mm2/s at 40ºC.
Partition co-efficient, n-octanol/water Data not available.
Pour Point circa -42ºC.
Stability
Stable.
Conditions to Avoid
Materials to Avoid

Eye Irritation
Skin Irritation
Skin Sensitisation
Carcinogenicity
Mutagenicity

X38 Cone Crusher
Other Information
hygiene. Skin contact should be minimised. Used oils may contain harmful impurities that have accumulated
during use. The concentration of such impurities will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled with caution and skin contact avoided as far as
possible.

Ecotoxicity/biodegradability studies have been performed on this product. Other information given is based on
the knowledge of similar products.
Mobility
will not be mobile.
Readily biodegradable.
Bioaccumulation
Not expected to bioaccumulate significantly.
Ecotoxicity
potential.
quantities.
Waste Disposal
Product Disposal
Container Disposal

X38 Cone Crusher
EC Symbols None.

Factories Act 1961
been introduced.
References
European Model Code of Safe Practice in the Storage and Handling of Petroleum Products. EN 374-2:1994
Protective gloves against chemicals and micro-organisms
testing, marking
EN 405:1992 Respiratory protective devices - valved filtering half masks to protect against gases or gases and
particles - requirements, testing, marking.
Restrictions
0151-350-4000.
Further Information

X38 Cone Crusher
of the product.
... End Of SDS ...

X38 Cone Crusher
ANTIFREEZE CONCENTRATE
Data Sheet No. L84042 Revision : 23 08 2004 REPLACES L84042 :
This data sheet has been prepared in accordance with the requirements of the Data Sheet Directive 91/155/EEC.
RECOMMENDED USES
Antifreeze Concentrate is recommended for use as :
an antifreeze
If Antifreeze Concentrate is used for a purpose not covered in this section, Shell UK Ltd would be grateful to receive information
on the application.
KNOWN MISUSES/ABUSES
Antifreeze Concentrate is not to be used as :
The most common misuse is that of ingestion by children. For this reason, Antifreeze Concentrate contains an aversive agent. It is
most important that Antifreeze Concentrate be kept safely out of reach or locked away.
The disposal of Antifreeze Concentrate to soil, watercourses and drains is a legal offence.
1: IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING
PRODUCT : ANTIFREEZE CONCENTRATE
COMPANY : SHELL UK OIL PRODUCTS LIMITED
TECHNICAL CONTACT: PRODUCT HSE DEPARTMENT
ADDRESS : STANLOW MANUFACTURING COMPLEX,

PO BOX 3, ELLESMERE PORT, CH65 4HB
TELEPHONE : 0151-350-4000
EMERGENCY TELEPHONE NUMBER : 0151-350-4595
2: COMPOSITION/INFORMATION ON INGREDIENTS
Antifreeze Concentrate is a preparation manufactured from ethanediol (ethylene glycol), additives and a taste aversive agent.
CONC. COMPONENT EINECS CLASS RISK PHRASES
>90% Ethanediol 203-473-3 Xn R22 Harmful if swallowed
Exposure limit values exist for the following constituents:
Ethanediol
3: HAZARD IDENTIFICATION
Antifreeze Concentrate is classified as dangerous for supply.
Antifreeze Concentrate is not classified as dangerous for conveyance.
It contains ethanediol to which exposure limits apply.
Ethanediol is readily biodegradable and poses a significant risk of oxygen deletion in aquatic systems.
L84042 23 : 08 : 04 Page 1 of 8

X38 Cone Crusher
4: FIRST AID MEASURES
INHALATION
Remove the person affected to fresh air. If rapid recovery does not occur, obtain medical attention.
SKIN
Wash contaminated skin with water. Use soap if available. Do not delay.
EYES
Flush the eye with copious quantities of water for up to 10 minutes. Refer for medical attention.
INGESTION
The normal advice given in the case of ingestion of hydrocarbon products is that vomiting should be avoided due to the risk
of aspiration into the lungs, however, owing to the toxic effects and rapid absorption from the stomach, this advice is modified
for Antifreeze Concentrate as follows :
SEEK QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
IF THE PATIENT IS UNCONSCIOUS, DO NOT INDUCE VOMITING.
WITH A CONSCIOUS PATIENT, if hospital assistance is not likely to be immediately available, attempt to induce vomiting.
SHOW A COPY OF THIS DATA SHEET TO THE PHYSICIAN,

draw attention to "Notes for Doctors" in Section 11 below.
5: FIRE-FIGHTING MEASURES
Extinguishants - Large Fire : Alcohol Resistant Foam/Water Fog - NEVER USE WATER JET
- Small Fire : Alcohol Resistant Foam/Water Fog/Dry Powder/CO2/Sand/Earth
Special Protective Equipment for Firefighters
The choice of protective equipment must only be undertaken in the light of a dynamic risk assessment by the officer in charge
of the incident. Whilst the content of this section may inform the choice of protective equipment used, the choice of protective
equipment will be highly dependent on local conditions.
For large fires, the officer in charge may consider; self contained breathing apparatus (EN 137).
Further guidance on protective equipment for professional fire fighters can be obtained from the home office.
DECOMPOSITION PRODUCTS
Refer to section 10 - stability and reactivity.
6: ACCIDENTAL RELEASE MEASURES
Extinguish naked flames, avoid contact with skin, eyes, and clothing. Wear plastic or rubber gloves, goggles or face shield
and boots. Make best endeavours to prevent entry to drains or watercourses.
LARGE SPILLS should be bunded by a suitable medium such as sand or earth. The liquid should be reclaimed directly or in
an adsorbent medium and then transferred to suitable, clearly marked containers and disposed of in accordance with local
byelaws and the requirements of the Environmental Protection Act 1990. Any containers used to collect the spilled material
or absorbent should be labelled to indicate contents and hazards.
SMALL SPILLS should be soaked up with sand or earth and disposed of as for large spills.
L84042 23 : 08 : 04 Page 2 of 8

X38 Cone Crusher
7: HANDLING AND STORAGE
HANDLING
Antifreeze Concentrate does not require any special handling techniques, but it should be handled in suitable containers and
spillage avoided. Avoid contact with skin, eyes and clothing. Do not breathe mists, aerosols or vapours. Maximum handling
temperature 60 Deg. C.
STORAGE
The storage of Antifreeze Concentrate is not subject to any special controls or restrictions. It should be stored in properly
designed, closable, labelled containers, eg mild steel or high density polyethylene (HDPE). Keep away from children,
foodstuffs and animal feed.
8: EXPOSURE CONTROLS/PERSONAL PROTECTION
EXPOSURE LIMIT VALUES
The following limits are taken from The Health and Safety Executive's Guidance Note EH40 Occupational Exposure Limits
2002.
UK Occupational Exposure Standards :
Ethanediol, particulate 10 mg/cubic metre 8-hour TWA value
Ethanediol, vapour 60 mg/cubic metre 8-hour TWA value

125 mg/cubic metre 15-min TWA value
RECOMMENDED MONITORING PROCEDURES
Reference should be made to HSE's publication Methods for the Determination of Hazardous Substances (MDHS) 14/3 and
88.
PERSONAL PROTECTIVE EQUIPMENT
The use of personal protective equipment is only one aspect of an integrated approach to the Control Of Substances
Hazardous to Health.
The management of Health and Safety at Work Regulations 1992 require employers to identify and evaluate the risks to health
and to implement appropriate measures to eliminate or minimise those risks.
The choice of personal protective equipment is highly dependent upon local conditions, e.g. exposure to other chemical
substances and micro-organisms, thermal hazards (protection from extremes of cold and heat), electrical hazards, mechanical
hazards and appropriate degree of manual dexterity required to undertake an activity.
Whilst the content of this section may inform the choice of personal protective equipment used, the limitations of any data
which can be provided must be fully understood, e.g. personal protective equipment chosen to protect employees from
occasional splashes maybe entirely inadequate for activities involving partial or complete immersion.
If the levels of vapour or particulate in air are likely to exceed the occupational exposure standards then consideration should
be given to the use of local exhaust ventilation to reduce personal exposure. The choice of personal protective equipment
should only be undertaken in the light of a full COSHH and risk assessment by a suitably qualified competent person ( e.g.
a professionally qualified occupational hygienist).
Effective protection is only achieved by correctly fitting and well maintained equipment and employers should ensure that
appropriate training is given. All personal protective equipment should be regularly inspected and replaced if defective.
In the first instance, further guidance maybe obtained through HSE's publication "COSHH - a brief guide to the regulations"
(INDG136(rev1)).
Hand Protection :-
Chemical protective gloves are made from a wide range of materials, but there is no single glove material ( or combination
of materials) which gives unlimited resistance to any individual or combination of substances or preparations. The extent of
L84042 23 : 08 : 04 Page 3 of 8

X38 Cone Crusher
the breakthrough time will be affected by a combination of factors which include permeation, penetration, degradation, use
pattern ( full immersion, occasional contacts) and how the glove is stored when not in use.
Theoretical maximum levels of protection are seldom achieved in practice and the actual level of protection can be difficult to
assess.
Effective breakthrough time should be used with care and a margin of safety should be applied. HSE guidance on protective
gloves recommends a 75% safety factor to be applied to any figures obtained in a laboratory test.
Nitrile gloves may offer relatively long breakthrough times and slow permeation rates. Test data, e.g breakthrough data
obtained through test standard EN374-3:1994 are available from reputable equipment suppliers.
Personal hygiene is a key element of effective hand care. Gloves must only be worn on clean hands. After using gloves, hands
should be washed and dried thoroughly. A non perfumed moisturiser should be applied.
At standard temperature and pressure, the Occupational Exposure Standards are unlikely to be exceeded.
Care should be taken to keep exposures below applicable occupational exposure limits. If this cannot be achieved, use of a
respirator fitted with an organic vapour cartridge combined with a particulate prefilter should be considered.
Half masks (EN 149) or valved half masks( EN 405) in combination with type A2 (EN 141) and P2/3 (EN 143) prefilters maybe
considered.
If Antifreeze Concentrate is subjected to elevated temperatures, say, half masks (EN 149) or valved half masks( EN 405) in
Eye Protection
Goggles conforming to a minimum standard of BS EN 166 345B should be considered if there is a possibility of eye contact
with Antifreeze Concentrate through splashing.
Higher rated eye protection must be considered for highly hazardous operations or work areas, employees involved in
metalworking operations such as chipping, grinding or cutting may require additional protection to avert injury from fast moving
particles or broken tools.
9: PHYSICAL AND CHEMICAL PROPERTIES
Physical State : Liquid at ambient temperature

Appearance : Dyed or colourless
Odour : Characteristic
Acidity/Alkalinity : pH 7-9 (solution in water at 50gms/100mls)
Initial Boiling Point : >150 Deg. C.
Freezing Point : <-30 Deg. C. (50% solution in water)
Flashpoint : >100 Deg. C.
Flammability : Not applicable
Autoflammability : 417 Deg. C. *
Flammability Limits - Upper : Not determined
- Lower : 3.0 % vol. *
Explosive Properties : Not applicable
Oxidising Properties : Not applicable
Vapour Pressure @ 20 Deg. C. : <10 Pa
Relative Density @ 20 Deg. C. : 1.12-1.14
Solubility : Water Solubility : Completely miscible
Fat solubility/solvent : Not determined
Partition Coefficient, n-octanol water : >1.0 *
Vapour Density (Air =1) : Not determined
Viscosity @ 20 Deg. C. : Not determined
Values marked with a * refer to ethanediol
L84042 23 : 08 : 04 Page 4 of 8

X38 Cone Crusher
10: STABILITY AND REACTIVITY
CONDITIONS TO AVOID
Extremes of temperature. Store between 0 and 50 Deg. C.
MATERIALS TO AVOID
Strong oxidising agents, eg. chlorates which may be used in agriculture.
The substances arising from the thermal decomposition of these products will largely depend upon the conditions bringing
about decomposition. The following substances may be expected from normal combustion :
Carbon Dioxide Unidentified Organic and Inorganic Compounds

Carbon Monoxide Particulate Matter
Water Nitrogen Oxides
11: TOXICOLOGICAL INFORMATION
Basis of Assessment
Toxicological data may not have been determined specifically for all end points ( e.g. mutagenicity, carcinogenicity,
reproductive toxicity, repeated dose and acute toxicity, corrosivity, irritation, sensitisation etc ) for this substance/preparation.
Assessment will be based on a combination of test data, human experience, toxicological data generated on similar
components and the conventional method.
Antifreeze Concentrate is classified as harmful by ingestion (deaths have been reported on swallowing large quantities). The
toxicity of ethanediol is principally due to it's metabolites. Renal damage has been observed in man with the deposition of
oxalate crystals.
At very high doses in animal experiments, foetotoxicity has been observed, but it's relevance to man has still to be clarified.
Antifreeze Concentrate contains an aversive agent which has an extremely bitter taste.
ACUTE HEALTH HAZARDS AND ADVICE
INHALATION
Due to its low vapour pressure, Antifreeze Concentrate is not considered likely to present an inhalation hazard at ambient
temperature. At elevated temperatures, the vapour may irritate the respiratory tract.
Precautions :
Inhalation of vapour, mists and aerosols should be avoided. If this cannot be achieved by safe working practices, suitable
respiratory protection should be used.
First Aid :
Remove the person affected to fresh air. If rapid recovery does not occur, obtain medical attention.
SKIN
Antifreeze Concentrate is expected to be slightly irritating to the skin and is harmful by skin absorption on prolonged or
repeated exposure.
Precautions :
All contact must be avoided by the use of suitable protective clothing Launder contaminated clothing before reusing.
L84042 23 : 08 : 04 Page 5 of 8

X38 Cone Crusher
First Aid :
Wash contaminated skin with water. Use soap if available.
EYES
Antifreeze Concentrate is expected to be moderately, possibly severely, irritating to the eye.
Precautions :
If there is a risk of splashing while handling the liquid, suitable eye protection should be used.
First Aid :
Do not delay. Flush the eye with copious quantities of water for up to 10 minutes. Refer for medical attention.
INGESTION
Ingestion of ethanediol may lead to serious intoxication, and possibly death. There may be effects on the central nervous
system, on the cardio-pulmonary system, and on the kidneys, with renal failure. Ingestion of as little as 100 millilitres may be
fatal for an adult. Antifreeze Concentrate is rapidly absorbed causing symptoms resembling alcohol intoxication, and
cardio-vascular effects. Death may occur from renal or hepatic failure : survivors usually have complete recovery of renal
function, although cerebral damage may be permanent.
Precautions :
Accidental ingestion is unlikely except in the case of children. Normal handling and hygiene precautions to avoid ingestion,
especially by keeping out of reach of children.
First Aid :
The normal advice given in the case of ingestion of hydrocarbon products is that vomiting should be avoided owing to risks
of aspiration into the lungs. Owing to the toxic effects and rapid absorption from the stomach, this advice is modified for
Antifreeze Concentrate as follows :
SEEK QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
IF THE PATIENT IS UNCONSCIOUS, DO NOT INDUCE VOMITING.
WITH A CONSCIOUS PATIENT, if hospital assistance is not likely to be immediately available, attempt to induce vomiting.
SHOW A COPY OF THIS DATA SHEET TO THE PHYSICIAN.
CHRONIC HEALTH HAZARD AND ADVICE
Continued exposure to vapour of Antifreeze Concentrate can induce unconsciousness, nystagmus and lymphocyosis. Death
from ingestion of the liquid is due to renal or hepatic failure. Survivors usually have complete recovery of renal function.
Cerebral damage may however be permanent. There is no human or animal evidence for carcinogenicity or mutagenicity.
HEALTH ADVICE TO PHYSICIANS
Treat by observation and supportive measures as indicated by the patient's condition.
The essentials of therapy are :
1. Supportive treatment of respiratory distress and shock.

2. Correction of metabolic acidosis and hypocalcemia.
3. Rapid and sustained diuresis when possible with the use of hypertonic mannitol.
4. Immediate peritoneal or haemodialysis.
5. Thiamine and pyridoxine supplements.
6. Intravenous administration of ethanol if the diagnosis is recognised within 6 hours after ingestion, and
7. Treatment for renal failure with dialysis as needed to keep patient free from signs and symptoms of uraemia.
L84042 23 : 08 : 04 Page 6 of 8

X38 Cone Crusher
12: ECOLOGICAL INFORMATION
Ecotoxicological data may not have been determined specifically for all end points for this substance/preparation. Assessment
will be based on a combination of test data, other available evidence, ecotoxicological data generated on similar components
and the conventional method.
Antifreeze Concentrate should be managed in the environment as a preparation at most slightly toxic but posing an indirect
hazard to the aquatic environment because of ready biodegradation leading to oxygen depletion. Avoid gross contamination
of the soil. Minimise contamination of water because of deoxygenation hazard. Spilled material should be contained and
removed as completely as possible. Final traces can be dispersed with water.
AIR
Antifreeze Concentrate is a mixture of non-volatile components, which are not expected to be released to air in any significant
quantities.
WATER
If released to water, Antifreeze Concentrate will dissolve. In view of deoxygenation hazard, consider dilution or (artificial)
reaeration. It will not bioaccumulate significantly.
SOIL
If released to soil Antifreeze Concentrate is highly mobile and will, in significant quantities, permeate to lower soil levels and
may reach groundwater in which it will dissolve.
13: DISPOSAL CONSIDERATIONS
Antifreeze Concentrate should be disposed of to a licensed waste contractor.
Any disposal route must satisfy the requirements of the of the Environmental Protection Act, 1990, the Environment Act 1995,
and should comply with any local byelaws. byelaws.
Antifreeze Concentrate is controlled by the Special Waste Regulations 1996.
Envirowise offers free advice through a national helpline. Initial contact by industry and commerce should be made to the
Environment and Energy helpline ( 0800 585 794). The Envirowise programme is sponsored by Government and seeks to
encourage good practice in environmental protection technology and techniques.
Further guidance can also obtained from the local environment agency agency office.
14: TRANSPORT INFORMATION
Not Dangerous for Conveyance
15: REGULATORY INFORMATION
Dangerous for Supply
Category of Danger : Harmful
Symbols : St Andrew's Cross
Risk Phrases : Harmful if swallowed
Safety Phrases: S2 Keep out of reach of Children

S24/25 Avoid contact with skin and eyes
S46 If swallowed, seek medical advice immediately
and show this container or label
Contains : Ethanediol
L84042 23 : 08 : 04 Page 7 of 8

X38 Cone Crusher
Additional Information
Safety data sheet available on request
LEGISLATION
Consumer Protection Act 1987

Environmental Protection Act 1990
Environment Act 1995
Factories Act 1961
Chemical (Hazards, Information, and Packaging for Supply) Regulations
Control of Substances Hazardous to Health Regulations
Dangerous Substances in Harbour Areas Regulations
Road Traffic (Carriage of Dangerous Substances in Packages etc.) Regulations
Road Traffic (Carriage of Dangerous Substances in Road Tankers and Tank Containers) Regulations
Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
Special Waste Regulations 1996
Health and Safety ( First Aid) Regulations 1981
Personal Protective Equipment ( EC Directive) Regulations 1992
16: OTHER INFORMATION
GUIDANCE NOTES
UK Chemicals Regulatory Atlas, An Overview of how to guide your chemical through to

regulatory compliance (DTI).
HSG71 The storage of packaged dangerous substances

EH/40 Occupational Exposure Limits
MS24 Health surveillance of occupational skin disease
HSG 53 The selection, use and maintenance of respiratory protective
equipment: A practical guide
HSG 206 Cost and effectiveness of chemical protective gloves for the
workplace: Guidance for employers and health and safety specialists.
HSG 136 Workplace transport safety : guidance for employers
INDG234 (rev) Are you Involved in the Carriage of Dangerous Goods by Road or Rail.
OTHER LITERATURE
L84042 23 : 08 : 04 Page 8 of 8

X38 Cone Crusher
ANTIFREEZE CONCENTRATE
Data Sheet No. L84042 Revision : 23 08 2004 REPLACES L84042 :
RECOMMENDED USES
Antifreeze Concentrate is recommended for use as :
an antifreeze
If Antifreeze Concentrate is used for a purpose not covered in this section, Shell UK Ltd would be grateful to receive information
on the application.
Antifreeze Concentrate is not to be used as :
The most common misuse is that of ingestion by children. For this reason, Antifreeze Concentrate contains an aversive agent. It is
most important that Antifreeze Concentrate be kept safely out of reach or locked away.
The disposal of Antifreeze Concentrate to soil, watercourses and drains is a legal offence.
PRODUCT : ANTIFREEZE CONCENTRATE

TELEPHONE : 0151-350-4000
Antifreeze Concentrate is a preparation manufactured from ethanediol (ethylene glycol), additives and a taste aversive agent.
>90% Ethanediol 203-473-3 Xn R22 Harmful if swallowed
Ethanediol
Antifreeze Concentrate is classified as dangerous for supply.
Antifreeze Concentrate is not classified as dangerous for conveyance.
It contains ethanediol to which exposure limits apply.
Ethanediol is readily biodegradable and poses a significant risk of oxygen deletion in aquatic systems.
L84042 23 : 08 : 04 Page 1 of 8

X38 Cone Crusher
SHELL AGRICULTURAL GAS OIL
Data Sheet No. F32002 Revision : 02 10 2002 REPLACES F32002 : 11 01 01
RECOMMENDED USES
Shell Agricultural Gas Oil is recommended for use as :
a fuel for small industrial boilers for horticultural and agricultural space heating applications, furnaces and dryers.
If Shell Agricultural Gas Oil is used for a purpose not covered in this section, Shell UK Ltd would be grateful to receive information
on the application.
Shell Agricultural Gas Oil is not to be used as :
a solvent or cleaning agent. It should never be siphoned by sucking the liquid up a tube by mouth, or stored near sources of heat
or ignition.
The disposal of Shell Agricultural Gas Oil to soil, watercourses and drains is a legal offence.
PRODUCT : SHELL AGRICULTURAL GAS OIL

TELEPHONE : 0151-350-4000
Shell Agricultural Gas Oil is a preparation manufactured from gas oils, derived from crude petroleum, and additives, none of
which impart any additional hazard to the finished product.
The hydrocarbon components will include straight-run gas oil, and may contain vacuum and/or cracked gas oil components.
| It is a requirement of H.M. Customs and Excise that all reduced duty fuels contain Quinizarin and C.I. Solvent Red 24.
| Rebated fuels marketed within the European Union must also contain C.I. Solvent Yellow 124. Shell Agricultural Gas Oil
| contains C.I.Solvent Red 24, Quinizarin and C.I. Solvent Yellow 124 at 4 ppm, 1.75 ppm and 6 ppm respectively.
The following components, which have health effects, are present at significant concentrations.
< 100% Fuels, diesel 269-822-7 Xn R40 Limited evidence of a carcinogenic effect
Xn R65 Harmful: may cause lung damage if swallowed
R66 Repeated exposure may cause skin dryness and
cracking
| N R51/53 Toxic to aquatic organisms, may cause long-term
| adverse effects in the aquatic environment
None.
F32002 03 : 10 : 02 Page 1 of 8

X38 Cone Crusher
Shell Agricultural Gas Oil is classified for supply purposes as : Harmful ( R40: Limited evidence of a carcinogenic effect and
R65: Harmful: may cause lung damage if swallowed), and Dangerous for the Environment ( R51/53 Toxic to aquatic
organisms, may cause long-term adverse effects in the aquatic environment).
Shell Agricultural Gas Oil satisfies the criteria for the additional risk phrase - R66: Repeated exposure may cause skin dryness
or cracking.
Shell Agricultural Gas Oil is a combustible liquid, which may explode under certain conditions, e.g. in the presence of
electrostatic charges generated, for example, during pumping or tank cleaning or by other sources of ignition or flame
impingement on containers.
Accidental ingestion can lead to vomiting and aspiration into the lungs, which can result in chemical pneumonitis, which can
be fatal.
Prolonged and repeated skin contact can lead to defatting of the skin, drying, cracking, dermatitis, erythema, oil acne and oil
folliculitis. Warty growths have occurred and these can become cancerous.
Exposure to high vapour concentrations can lead to nausea, headache and dizziness. Excessive and prolonged exposure to
mists may cause a chronic inflammatory reaction of the lungs and a form of pulmonary fibrosis.
It should be assumed that the flashpoint of Shell Agricultural Gas Oil is equal to or less than 60.5 Deg. C. unless the carrier
has obtained contrary test data. Consequently, Shell Agricultural Gas Oil is classified for conveyance purposes as a
flammable liquid.
Shell Agricultural Gas Oil will not biodegrade in anaerobic conditions and, hence, can be persistent. It contains components
which have a high potential to bioaccumulate.
4: FIRST AID MEASURES
INHALATION
Remove the affected person to fresh air. If breathing has stopped administer artificial respiration. Give cardiac massage if
necessary. If the person is breathing, but unconscious, place in the recovery position. Obtain medical assistance immediately.
SKIN
Flush the contaminated skin with water. Use soap if available. Contaminated clothing should be soaked with water, removed,
and laundered before reuse.
EYES
Flush the eye with copious quantities of water. If irritation persists refer for medical attention.
INGESTION
DO NOT INDUCE VOMITING. If ingestion is suspected, wash out the mouth with water, and send to hospital immediately.
Show this Data Sheet to the physician drawing attention to "Notes for Doctors" in Section 11 below.
5: FIRE-FIGHTING MEASURES
Extinguishants - Large Fire : Foam/Water Fog - NEVER USE WATER JET

- Small Fire : Foam/Dry Powder/CO2/Sand/Earth
6: ACCIDENTAL RELEASE MEASURES
LAND SPILLAGES
IMMEDIATE EMERGENCY ACTION

Clear people away from the area to a safe place
Do not operate electrical equipment unless flameproof
Summon aid of emergency services if warranted
Treat or refer casualties if necessary
FURTHER ACTION - FIRE
F32002 03 : 10 : 02 Page 2 of 8

X38 Cone Crusher
9: PHYSICAL AND CHEMICAL PROPERTIES
Physical State : Mobile liquid at ambient temperature

Appearance : Clear Red/ Brown
Odour : Characteristic
Acidity/Alkalinity : Not applicable
Initial Boiling Point : 180 Deg. C.
Flashpoint : > 56 Deg. C.
Flammability : Not applicable
Autoflammability : ca. 220 Deg. C.
Flammability Limits - Upper : 6 % vol.
- Lower : 1 % vol.
Explosive Properties : Not applicable
Oxidising Properties : Not applicable
Vapour Pressure @ 20 Deg. C. : <0.1 k.Pa
Relative Density @ 15 Deg. C. : 0.82 to 0.87
Solubility : Water Solubility : Very Low
Fat solubility/solvent : Not available
Partition Coefficient, n-octanol water : 3 to >6
Vapour Density (Air =1) : >5
Viscosity @ 40 Deg. C. : 2 to 5 cSt.
10: STABILITY AND REACTIVITY
CONDITIONS TO AVOID
Sources of ignition. Extremes of temperature.
MATERIALS TO AVOID
Strong oxidising agents, eg. chlorates which may be used in agriculture.
The substances arising from the thermal decomposition of these products will largely depend upon the conditions bringing
about decomposition. The following substances may be expected from normal combustion :
Carbon Dioxide Unburnt Hydrocarbons

Carbon Monoxide Unidentified Organic and Inorganic Compounds
Water Nitrogen Oxides
Particulate Matter Sulphur Oxides
Polycyclic Aromatic Hydrocarbons
11: TOXICOLOGICAL INFORMATION
ACUTE HEALTH HAZARDS AND ADVICE
Shell Agricultural Gas Oil is classified as harmful owing to the aspiration hazard.
Shell Agricultural Gas Oil carries the additional risk phrase - repeated exposure may cause skin dryness or cracking.
The main hazards are: in the case of inhalation of higher vapour concentrations, of effects on the central nervous system ;
in the case of skin contact of, defatting and irritation ; in the unlikely event of ingestion, of aspiration into the lungs with possible
resultant chemically induced pneumonia.
Exposure to higher vapour concentrations can lead to nausea, headache, dizziness, loss of consciousness, and, in oxygen
deficient environments, death. A person exposed to significant concentrations of vapour may display drunken behaviour, and
his judgement can be impaired.
If the product is accidentally ingested, irritation to the gastric mucous membranes can lead to vomiting. If this occurs, there is
a high probability of the product being aspirated into the lungs, which can lead to chemical pneumonitis which can be fatal.
F32002 03 : 10 : 02 Page 4 of 8

X38 Cone Crusher
INHALATION
Under normal conditions of use Shell Agricultural Gas Oil is not expected to present an inhalation hazard.
Precautions :
Inhalation of vapours should be avoided. Where, exceptionally, higher concentrations of the vapour may be encountered, e.g.
in the event of a spillage in a badly ventilated area, persons should not be allowed to enter the area, even in an emergency,
until the atmosphere has been checked and passed as safe for entry by a competent person.
First Aid :
Remove the affected person to fresh air. If breathing has stopped administer artificial respiration. Give cardiac massage if
necessary. If the person is breathing, but unconscious, place in the recovery position. Obtain medical assistance immediately.
SKIN
Shell Agricultural Gas Oil is slightly irritating to the skin, and has a defatting action on the skin.
Precautions :
Avoid contact with the skin by the use of suitable protective clothing.
First Aid :
Flush the contaminated skin with water. Use soap if available. Contaminated clothing should be soaked with water, removed,
and laundered before reuse.
EYES
Shell Agricultural Gas Oil may cause discomfort to the eye.
Precautions :
If there is a risk of splashing while handling the liquid, suitable eye protection should be used.
First Aid :
Flush the eye with copious quantities of water. If irritation persists refer for medical attention.
INGESTION
Shell Agricultural Gas Oil is classified as harmful owing to the aspiration hazard. Ingestion can lead to vomiting and aspiration
into the lungs, which can result in chemical pneumonitis, which can be fatal.
Precautions :
Accidental ingestion is unlikely. Normal handling and hygiene precautions should be taken to avoid ingestion.
First Aid :
DO NOT INDUCE VOMITING Wash out the mouth with water, and, if ingestion is suspected, send to hospital immediately.
Show this Data Sheet to the physician drawing attention to "Notes for Doctors" below.
CHRONIC HEALTH HAZARD AND ADVICE
Shell Agricultural Gas Oil is classified as a category 3 carcinogen.
The main hazards arise from skin contact and in the inhalation of mists.
F32002 03 : 10 : 02 Page 5 of 8

X38 Cone Crusher
Skin contact over prolonged and repeated periods can lead to defatting of the skin, dermatitis, erythema, oil acne and oil
folliculitis. Where occupational and personal hygiene practices have been of a poor standard, warty growths have occurred
and these can become cancerous.
Excessive and prolonged inhalation of mists may cause a chronic inflammatory reaction of the lungs and a form of pulmonary
fibrosis.
NOTES FOR DOCTORS
HIGH PRESSURE INJECTION INJURIES
High pressure injection injuries require surgical intervention and possibly steroid therapy to minimise tissue damage and loss
of function. Because entry wounds are small and do not reflect the seriousness of the underlying damage, surgical exploration
to determine the extent of involvement may be necessary. Local anaesthetics or hot soaks should be avoided because they
can contribute to swelling, vasospasm and ischaemia. PROMPT surgical decompression, debridement and evacuation of
foreign material should be performed under general anaesthetic, and wide exploration is essential.
INGESTION AND ASPIRATION OF PETROLEUM PRODUCTS
There may be a risk to health where low viscosity products are aspirated into the lungs following vomiting, although this is
uncommon in adults. Such aspiration would cause intense local irritation and chemical pneumonitis. Children, and those in
whom consciousness is impaired, will be more at risk. Emesis of lubricants is not usually necessary, unless a large amount
has been ingested, or some other compound has been dissolved in the product. If this is indicated - for example, when there
is rapid onset of CNS depression from a large ingested volume - gastric lavage under controlled hospital conditions, with full
protection of the airway is required. Supportive care may include oxygen, arterial blood gas monitoring, respiratory support
and, if aspiration has occurred, treatment with corticosteroids and antibiotics. Seizures should be controlled with Diazepam,
or appropriate equivalent drug.
12: ECOLOGICAL INFORMATION
Shell Agricultural Gas Oil contains fuels, diesel which is classified as toxic to aquatic organisms/ may cause long-term adverse
effects in the aquatic environment.
AIR
Shell Agricultural Gas Oil is a mixture of mainly non-volatile components, which when released to air will react rapidly with
hydroxyl radicals and ozone.
WATER
If released to water, Shell Agricultural Gas Oil will evaporate at a very slow rate. A small proportion will dissolve. Dissolved
components will be either absorbed in sediments or evaporate to air. In aerobic water and sediments they will biodegrade,
but in anaerobic conditions they will persist.
SOIL
Small volumes released on land will evaporate at a very slow rate, with a proportion of the product being absorbed in the upper
soil layers and being subject to biodegradation. Larger volumes may penetrate into anaerobic soil layers in which the product
will persist. The product may reach the water table on which it will form a floating layer, and move along with the groundwater
flow. In this case the more soluble components, such as aromatics, will cause groundwater contamination.
13: DISPOSAL CONSIDERATIONS
Shell Agricultural Gas Oil is a special waste owing to its supply classification. It should be disposed of to a licensed waste
contractor. Any disposal route should comply with local byelaws and the requirements of the Environmental Protection Act,
1990.
F32002 03 : 10 : 02 Page 6 of 8

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14: TRANSPORT INFORMATION
It should be assumed that the flashpoint of Shell Agricultural Gas Oil is equal to or less than 60.5 Deg. C. unless the carrier
has obtained contrary test data.
UN Number : 1202
Proper Shipping Name : Gas Oil
Symbol : Flammable Liquid
Packing Group : III
Marine Pollutant : No
IATA/ICAO Hazard Class : 3
IMO Hazard Class : 3.3
Class : 3
Classification Code : F1
Hazard Identification No. : 30
Hazchem Code : 3|Z
15: REGULATORY INFORMATION
This material has been classified according to the requirements of the Chemicals ( Hazard Information and Packaging for
Supply) Regulations.
Dangerous for Supply
Symbols : St Andrew's Cross

| Dead Fish and Tree
Categories of Danger : Category 3 Carcinogen

Harmful
Risk Phrases : R40 Limited evidence of a carcinogenic effect

R65 Harmful: may cause lung damage if swallowed
R66 Repeated exposure may cause skin dryness or cracking
| R51/53 Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environ
Safety Phrases : S2 Keep out of the reach of children

S24 Avoid contact with the skin.
S36/37 Wear suitable protective clothing and gloves
| S61 Avoid release to the environment. Refer to special instructions /
| safety data sheets
S62 If swallowed, do not induce vomiting : seek medical advice immediately
and show this label or container
Contains : Fuels, diesel
16: OTHER INFORMATION
The references set out below give further information on specific aspects.
LEGISLATION
Consumer Protection Act 1987

Environmental Protection Act 1990
Factories Act 1961
Chemical (Hazards, Information, and Packaging for Supply) Regulations
Control of Substances Hazardous to Health Regulations
Dangerous Substances in Harbour Areas Regulations
Road Traffic (Carriage of Dangerous Substances in Packages etc.) Regulations
Road Traffic (Carriage of Dangerous Substances in Road Tankers and Tank Containers) Regulations
Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
Special Waste Regulations
F32002 03 : 10 : 02 Page 7 of 8

X38 Cone Crusher
GUIDANCE NOTES
CS/15 The cleaning and gas freeing of tanks containing flammable residues
HS(G)22 Electrical apparatus for use in potentially explosive atmospheres
HS(G)50 The storage of flammable liquids in fixed tanks (up to 10000m3 total capacity)
HS(G)51 The storage of flammable liquids in containers
HS(G)50 The storage of flammable liquids in fixed tanks (exceeding 10000m3 total capacity)
HS(G)140 The safe use and handling of flammable liquids
HS(G)71 The storage of packaged dangerous substances
EH/40 Occupational Exposure Limits
EH/58 The Carcinogenicity of Mineral Oils
MS24 Health surveillance of occupational skin disease
BRITISH STANDARDS
BS 799
Specification for Oil Burning Equipment
BS 2000
Methods of Test for Petroleum and its Products
BS 2869
Fuel Oils for Oil Engines and Burners for Non-Marine Use
BS 5345
Selection, Installation and Maintenance of Electrical Apparatus for Use in Potentially
Explosive Atmospheres
BS 5410 Oil Firing
BS 5958 Control of Undesirable Static Electricity
BS 6380 Low Temperature Properties and Cold Weather Use of Diesel Fuel and Gas Oils (Classes
A1, A2 and D of BS 2869)
OTHER LITERATURE
Institute of Petroleum Marketing Safety Code
Department of Trade - Code of Portable Tanks and Road Tank Vehicles for the Carriage of Liquid
Dangerous Goods in Ships
ADDRESSES
Concawe, Boulevard du Souverain 165 B - 1160 Brussels, Belgium

Institute of Petroleum, 61 New Cavendish Street, London W1
F32002 03 : 10 : 02 Page 8 of 8

X38 Cone Crusher
SAFETY DATA
SHEET
ATHENA EP 90 (Group 2)
Mineral oil based GL-4 gear oil
Product code: G010 Date of issue: 2nd October 2002
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE

COMPANY/UNDERTAKING
Identification of substance/preparation
Athena EP 90
Application
Automotive gear lubricant
For specific application advice see appropriate Technical Data Sheet or consult your eXOL representative
Company Identification
eXOL Lubricants Limited
All Saints Road
Wednesbury
West Midlands
WS10 9TS
Emergency Telephone Number

+44 (0) 121 568 6800
___________________________________________________________________
Chemical Composition
Highly refined mineral oil (IP 346 DMSO extract < 3%)
Proprietary performance additives.
Hazardous Components
No component is present at sufficient concentration to require a hazardous classification.
___________________________________________________________________
This material is not considered to be hazardous, but should be handled in accordance with good industrial
hygiene and safety practices.
USED ENGINE OILS

Used engine oil may contain hazardous components which have the potential to cause skin cancer.
See Toxicological Information, section 11 of this Safety Data Sheet.
___________________________________________________________________
Page 1 of 6 Athena EP 90

X38 Cone Crusher
SAFETY DATA
SHEET
4. FIRST-AID MEASURES
Eyes
Wash eye thoroughly with copious quantities of water, ensuring eyelids are held open. Obtain medical advice if
any pain or redness develops or persists.
Skin
Wash skin thoroughly with soap and water as soon as reasonably practicable. Remove heavily contaminated
clothing and wash underlying skin.
Ingestion
If contamination of the mouth occurs, wash out thoroughly with water.
Except as a deliberate act, the ingestion of large amounts of product is unlikely. If it should occur, do not induce
vomiting; obtain medical advice.
Inhalation
If inhalation of mists, fumes or vapour causes irritation to the nose or throat, or coughing, remove to fresh air. If
symptoms persist obtain medical advice.
Medical Advice
Treatment should in general be symptomatic and directed to relieving any effects.
___________________________________________________________________
5. FIRE-FIGHTING MEASURES
Use foam, dry powder or water fog. DO NOT USE water jets.
Fires in confined spaces should be dealt with by trained personnel wearing approved breathing apparatus.
Water may be used to cool nearby heat exposed areas/objects/packages. Avoid spraying directly into storage
containers because of the danger of boil-over.
Combustion Products
Toxic fumes may be evolved on burning or exposure to heat.
See Stability and Reactivity, Section 10 of this Safety Data Sheet.
___________________________________________________________________
Contain and recover spilled material using sand or other suitable inert absorbent material.
It is advised that stocks of suitable absorbent material should be held in quantities sufficient to deal with any
spillage which may be reasonably anticipated.
Spilled material may make surfaces slippery.
Protect drains from potential spills to minimise contamination. Do not wash product into drainage system.
In the case of large spills contact the appropriate authorities or telephone 0121-568-6800
In the case of spillage on water, prevent the spread of product by the use of suitable barrier equipment. Recover
product from the surface. Protect environmentally sensitive areas and water supplies.
___________________________________________________________________

X38 Cone Crusher
SAFETY DATA
SHEET
Handling Precautions
Avoid contact with eyes. If splashing is likely to occur wear a full face visor or chemical goggles as appropriate.
Avoid frequent or prolonged skin contact with fresh or used product.
Good working practices, high standards of personal hygiene and plant cleanliness must be maintained at all
times.
Wash hands thoroughly after contact.
Use disposable cloths and discard when soiled. Do not put soiled cloths into pockets.
Fire Prevention
Product contaminated rags, paper or material used to absorb spillages, represent a fire hazard, and should not be
allowed to accumulate. Dispose of safely immediately after use.
Storage Conditions
Store under cover away from heat and sources of ignition.
___________________________________________________________________
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
Exposure Limits
There is no appropriate occupational exposure limit for this material.
Ensure good ventilation.
Avoid, as far as reasonably practicable, inhalation of vapour, mists or fumes generated during use.
If vapour, mists or fumes are generated, their concentration in the workplace air should be controlled to the
lowest reasonably practicable level.
Protective Clothing
Wear face visor or goggles in circumstances where eye contact can accidentally occur.
If skin contact is likely, wear impervious protective clothing and/or gloves.
Protective clothing should be regularly dry cleaned. Change heavily contaminated clothing as soon as reasonably
practicable; dry clean, launder and preferably starch before re-use. Wash any contaminated underlying skin with
soap and water.
Respiratory protection is unnecessary, provided the concentration of vapour, mists or fumes is adequately
controlled.
The use of respiratory equipment must be strictly in accordance with the manufacturers' instructions and any
statutory requirements governing its selection and use.
_________________________________________________________________

X38 Cone Crusher
SAFETY DATA
SHEET

Typical Values
Grades: EP 90
Test Method Units
Physical state
Colour
Odour
Density @ 15°C ASTM D 1298 kg/m³ 891
Kinematic viscosity @ 40°C ASTM D 445 mm²/s 229.1
Kinematic viscosity @ 100°C ASTM D 445 mm²/s 19.85
Flash point (COC) ASTM D 93 °C 222
Pour point ASTM D 97 °C -11
___________________________________________________________________
Products of this type are stable and unlikely to react in a hazardous manner under normal conditions of use.
Hazardous polymerisation reactions will not occur.
This material is combustible.
Materials to Avoid
Avoid contact with strong oxidizing agents.

Thermal decomposition products will vary with conditions.
Incomplete combustion will generate smoke, carbon dioxide and hazardous gases, including carbon monoxide,
hydrogen sulphide and oxides of sulphur and phosphorus.
___________________________________________________________________
Eyes
Unlikely to cause more than transient stinging or redness if accidental eye contact occurs.
Skin
Unlikely to cause harm to the skin on brief or occasional contact but prolonged or repeated exposure may lead to
dermatitis.

X38 Cone Crusher
SAFETY DATA
SHEET
USED ENGINE OILS

Combustion products resulting from the operation of internal combustion engines contaminate engine oils during
use. Used engine oil may contain hazardous components which have the potential to cause skin cancer. Frequent
or prolonged contact with all types and makes of used engine oil must therefore be avoided and a high standard
of personal hygiene maintained.
Ingestion
Unlikely to cause harm if accidentally swallowed in small doses, though larger quantities may cause nausea and
diarrhoea.
Inhalation
At normal ambient temperatures this product will be unlikely to present an inhalation hazard because of its low
volatility.
May cause irritation to eyes, nose and throat due to exposure to vapour, mists or fumes.
May be harmful by inhalation if exposure to vapour, mists or fumes resulting from thermal decomposition
products occurs.
___________________________________________________________________
Mobility
Spillages may penetrate the soil causing ground water contamination.
Persistence and degradability

This product is inherently biodegradable.
Bioaccumulative potential
There is no evidence to suggest bioaccumulation will occur.
Aquatic toxicity
Spills may form a film on water surfaces causing physical damage to organisms. Oxygen transfer could also be
impaired.
___________________________________________________________________
Where possible, arrange for product to be recycled.

Dispose of via an authorised person/ licensed waste disposal contractor in accordance with local regulations.
Incineration may be carried out under controlled conditions provided that local regulations for emissions are met.
___________________________________________________________________
Not classified as hazardous for transport (ADR, RID, UN , IMO, IATA/ICAO).

___________________________________________________________________

X38 Cone Crusher
SAFETY DATA
SHEET
Not classified as hazardous for supply.

___________________________________________________________________
Compiled by:
Technical Department
eXOL Lubricants Limited
All Saints Road
Wednesbury
West Midlands
WS10 9TS
This data sheet and the health, safety and environmental information it contains is considered to be accurate as of
the date specified below. We have reviewed any information contained herein which we received from sources
outside eXOL Lubricants Limited. However, no warranty or representation, express or implied is made as to the
accuracy or completeness of the data and information contained in this data sheet.
Health and safety precautions and environmental advice noted in this data sheet may not be accurate for all
individuals and/or situations. It is the user's obligation to evaluate and use this product safely and to comply with
all applicable laws and regulations. No statement made in this data sheet shall be construed as a permission,
recommendation or authorization given or implied to practise any patented invention without a valid licence.
eXOL Lubricants Limited shall not be responsible for any damage or injury resulting from abnormal use of the
material, from any failure to adhere to recommendations, or from any hazards inherent in the nature of the
material.
___________________________________________________________________
Issue No. e1 Revision No: 0 Issued by: D Hall

October 2002 Date of Revision Approved by:

X38 Cone Crusher
Safety Data Sheet
Shell Omala Oil HD 220


Infosafe No. ACL4X NO/eng/C
Issued Date 09.06.2004
Product Type/Use Gear lubricant.

Shell Omala Oil HD 220 140000000728

A/S Norske Shell Emergency Tel.
Postboks 1154 Sentrum, 0107 Oslo
Beredskapstelefon : 22 66 50 00
Norway
Giftinformasjonen: 22591300
Telephone/Fax Number
22 66 50 00 / 22 66 51 48
Blend of polyolefins and additives.

Safety Hazards
Not classified as dangerous to the environment.

X38 Cone Crusher
Inhalation
attention.
Skin
Eye
Ingestion
Advice to Doctor
Specific Hazards
including carbon monoxide and unidentified organic and inorganic compounds.
Extinguishing Media
space.

X38 Cone Crusher
Handling
of risks must be made to help determine controls appropriate to local circumstances.
Storage
heat sources, and strong oxidizing agents.
Other Information
Exposure Limits
No Exposure Limit Established
Exposure Controls
The choice of personal protective equipment is highly dependent upon local conditions, e.g. exposure to other
chemical substances and micro-organisms, thermal hazards (protection from extremes of cold and heat),
electrical hazards, mechanical hazards and appropriate degree of manual dexterity required to undertake an
activity.
exposure.
Not normally required. If oil mist cannot be controlled, a respirator fitted with an organic vapour cartridge
combined with a particulate pre-filter should be used.
Hand Protection
be difficult to assess. Nitrile gloves may offer relatively long breakthrough times and slow permeation rates. Test

X38 Cone Crusher
data, e.g breakthrough data obtained through test standard EN374-3:1994 are available from reputable
equipment suppliers.
Eye Protection
tools.
Body Protection
Colour Amber.
Odour Characteristic.
pH Value Not applicable.
Flash Point circa 245ºC (PMCC).
Flammable Limits - Upper 10%(V/V) (typical).
Flammable Limits - Lower 1%(V/V) (typical).
Kinematic Viscosity circa 220 mm2/s at 40ºC.
Pour Point circa -48ºC.
Stability
Stable.
Conditions to Avoid
Materials to Avoid

X38 Cone Crusher


Eye Irritation
Skin Irritation
Skin Sensitisation
Carcinogenicity
Mutagenicity
Other Information
hygiene. Skin contact should be minimised. Used oils may contain harmful impurities that have accumulated
during use. The concentration of such impurities will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled with caution and skin contact avoided as far as
possible.

Mobility
will not be mobile.

X38 Cone Crusher

Bioaccumulation
Ecotoxicity
potential.
quantities.
Waste Disposal
Product Disposal
Container Disposal
EU Waste Disposal Code (EWC)
13 02 06 synthetic engine, gear and lubricating oils.
The number given to waste is associated to the appropriate usage. The user must decide if their particular
usage result in another waste code being assigned.
EC Symbols None.

Forskrift om liste over farlige stoffer (Stofflisten).
Forskrifter om klassifisering, merking m.v. av farlige kjemikalier.
Forskrift om farlig avfall.

X38 Cone Crusher
Administrative normer for forurensning i arbeidsatmosfære.

Forskrift om utarbeidelse og distribusjon av helse-, milj°- og sikkerhetsdatablad for farlige kjemikalier.
Norway Classification
Not classified as Dangerous Under Norwegian Law.
been introduced.
References
67/548/EEC - Dangerous Substances Directive.
1999/45/EC - Dangerous Preparations Directive.
91/155/EEC - Safety Data Sheet Directive.
98/24/EC - Protection of the Health and Safety of Workers from risks related to chemical agents at work.
89/686/EEC - Approximation of the laws of the member of states relating to personal protective equipment.
76/769/EEC - Restrictions of the marketing and use.
Relevant Comité Européen de Normalisation (CEN) standards giving specific requirements for personal
protective equipment.
Concawe Report 01/53 - Classification and labelling of petroleum substances according to the EU dangerous
substances directive.
Concawe Report 03/82 - Precautionary Advice on the Handling of Used Engine Oils
Concawe Report 01/97 - Petroleum Products - First Aid and Emergency Advice
Concawe Report 86/89 - Health Aspects of Workers Exposure to Oil Mists
Concawe Report 01/54 - Environmental Classification of Petroleum Substances - Summary Data and Rationale
EN 374-2:1994 Protective gloves against chemicals and micro-organisms
testing, marking
EN 405:1992 Respiratory protective devices - valved filtering half masks to protect against gases or gases and
particles - requirements, testing, marking.
Restrictions
22 66 50 00.
Further Information
of the product.
... End Of SDS ...

X38 Cone Crusher
MATERIAL SAFETY DATA SHEET

Revision Date: 12/17/2003
--------------------------------------------------------------------------------
SECTION 1 PRODUCT AND COMPANY IDENTIFICATION
--------------------------------------------------------------------------------
PRODUCT: Omala® Fluid HD 150

MSDS NUMBER: 400915E - 1
PRODUCT CODE(S): 65569
MANUFACTURER ADDRESS:SOPUS Products, P.O. Box 4453, Houston, TX. 77210-4453
TELEPHONE NUMBERS
Spill Information: (877) 242-7400
Health Information: (877) 504-9351
MSDS Assistance Number: (877) 276-7285
--------------------------------------------------------------------------------
SECTION 2 PRODUCT/INGREDIENTS
--------------------------------------------------------------------------------
CAS# CONCENTRATION INGREDIENTS

Synthetic Gear Oil
Mixture 90 - 98.99 %volume Synthetic hydrocarbon base oil (PAO)
Proprietary 1 - 4.99 %volume Polymer additives
--------------------------------------------------------------------------------
SECTION 3 HAZARDS IDENTIFICATION
--------------------------------------------------------------------------------
EMERGENCY OVERVIEW
Appearance & Odor: Pale yellow liquid. Mild odor.
Health Hazards: No known immediate health hazards.
Physical Hazards: No known physical hazards.
NFPA Rating (Health, Fire, Reactivity): 0, 1, 0
Hazard Rating:Least - 0 Slight - 1 Moderate - 2 High - 3
Extreme - 4
Inhalation:
Inhalation of vapors (generated at high temperatures only) or oil mist may
cause mild irritation of the nose, throat, and respiratory tract.
Eye Irritation:
Lubricating oils are generally considered no more than minimally irritating to
the eyes.
Skin Contact:
Lubricating oils are generally considered no more than minimally irritating to
the skin. Prolonged and repeated contact may result in defatting and drying
of the skin that may cause various skin disorders such as dermatitis,
folliculitis or oil acne.
Ingestion:
Lubricating oils are generally no more than slightly toxic if swallowed.
Signs and Symptoms:

Irritation as noted above.
Aggravated Medical Conditions:

Pre-existing eye, skin and respiratory disorders may be aggravated by exposure
to this product.
For additional health information, refer to section 11.

P 71 f 77 A di D

X38 Cone Crusher
--------------------------------------------------------------------------------
SECTION 4 FIRST AID MEASURES
--------------------------------------------------------------------------------
Inhalation:
Remove victim to fresh air and provide oxygen if breathing is difficult. Get
medical attention.
Skin:
Remove contaminated clothing and shoes and wipe excess from skin. Flush skin
with water, then wash with soap and water. If irritation occurs, get medical
attention. Do not reuse clothing until cleaned.
Eye:
Flush with water. If irritation occurs, get medical attention.
Ingestion:
Do not induce vomiting. In general, no treatment is necessary unless large
quantities of product are ingested. However, get medical attention.
Note to Physician:
In general, emesis induction is unnecessary in high viscosity, low volatility
products such as oils and greases.
--------------------------------------------------------------------------------
SECTION 5 FIRE FIGHTING MEASURES
--------------------------------------------------------------------------------
Flash Point [Method]: 500 ºF -510 ºF/260 ºC -265.56 ºC [ Cleveland Open

Cup]
Extinguishing Media:
Material will float and can be re-ignited on surface of water. Use water fog,
'alcohol foam', dry chemical or carbon dioxide (CO2) to extinguish flames. Do
not use a direct stream of water.
Fire Fighting Instructions:

Material will not burn unless preheated. Do not enter confined fire space
without full bunker gear (helmet with face shield, bunker coats, gloves and
rubber boots), including a positive pressure, NIOSH approved, self-contained
breathing apparatus.
--------------------------------------------------------------------------------
SECTION 6 ACCIDENTAL RELEASE MEASURES
--------------------------------------------------------------------------------
Protective Measures:
May burn although not readily ignitable.
Wear appropriate personal protective equipment when cleaning up spills. Refer

to Section 8.
Spill Management:
FOR LARGE SPILLS: Remove with vacuum truck or pump to storage/salvage vessels.
FOR SMALL SPILLS: Soak up residue with an absorbent such as clay, sand or
other suitable material. Place in non-leaking container and seal tightly for
proper disposal.
Reporting:
CERCLA: Product is covered by EPA's Comprehensive Environmental Response,
Compensation and Liability Act (CERCLA) petroleum exclusion. Releases to air,
land, or water are not reportable under CERCLA (Superfund).
P 72 f 77 A di D

X38 Cone Crusher
CWA: This product is an oil as defined under Section 311 of EPA's Clean Water
Act (CWA). Spills into or leading to surface waters that cause a sheen must be
reported to the National Response Center, 1-800-424-8802.
--------------------------------------------------------------------------------
SECTION 7 HANDLING AND STORAGE
--------------------------------------------------------------------------------
Precautionary Measures:
Wash with soap and water before eating, drinking, smoking, applying cosmetics,
or using toilet. Launder contaminated clothing before reuse. Properly
dispose of contaminated leather articles such as shoes or belts that cannot be
decontaminated. Avoid heat, open flames, including pilot lights, and strong
oxidizing agents. Use explosion-proof ventilation to prevent vapor
accumulation. Ground all handling equipment to prevent sparking.
Storage:
Store in a cool, dry place with adequate ventilation. Keep away from open
flames and high temperatures.
Container Warnings:
Keep containers closed when not in use. Containers, even those that have been
emptied, can contain explosive vapors. Do not cut, drill, grind, weld or
perform similar operations on or near containers.
--------------------------------------------------------------------------------
SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION
--------------------------------------------------------------------------------
Polyalphaolefin ACGIH TLV TWA: 5 mg/m3 STEL: 10 mg/m3

Polyalphaolefin OSHA PEL TWA: 5 mg/m3
EXPOSURE CONTROLS
Adequate ventilation to control airborne concentrations below the exposure
guidelines/limits.
PERSONAL PROTECTION
Personal protective equipment (PPE) selections vary based on potential
exposure conditions such as handling practices, concentration and ventilation.
Information on the selection of eye, skin and respiratory protection for use
with this material is provided below.
Eye Protection:
Safety glasses with side shields
Skin Protection:
Use protective clothing which is chemically resistant to this material.
Selection of protective clothing depends on potential exposure conditions and
may include gloves, boots, suits and other items. The selection(s) should
take into account such factors as job task, type of exposure and durability
requirements.
Published literature, test data and/or glove and clothing manufacturers

indicate the best protection is provided by:
Neoprene, or Nitrile Rubber
Respiratory Protection:
If engineering controls do not maintain airborne concentrations to a level
which is adequate to protect worker health, an approved respirator must be
worn. Respirator selection, use and maintenance should be in accordance with
the requirements of the OSHA Respiratory Protection Standard, 29 CFR 1910.134.
Types of respirator(s) to be considered in the selection process include:

For Mist: Air Purifying, R or P style NIOSH approved respirator.
For Vapors: Air Purifying, R or P style prefilter & organic cartridge,
NIOSH approved respirator. Self-contained breathing apparatus for use in
environments with unknown concentrations or emergency situations.
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--------------------------------------------------------------------------------
SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES
--------------------------------------------------------------------------------
Appearance & Odor: Pale yellow liquid. Mild odor.

Substance Chemical Family: Lubricants
Appearance: Pale yellow liquid.
Flash Point: 500 ºF - 510 ºF [Cleveland Open Cup]
Pour Point: > -40 ºF
Specific Gravity: 0.85
Viscosity: 220 cSt - 460 cSt @ 40 ºC
--------------------------------------------------------------------------------
SECTION 10 REACTIVITY AND STABILITY
--------------------------------------------------------------------------------
Stability:
Material is stable under normal conditions.
Conditions to Avoid:
Avoid heat and open flames.
Materials to Avoid:
Avoid contact with strong oxidizing agents.
Hazardous Decomposition Products:

Thermal decomposition products are highly dependent on combustion conditions.
A complex mixture of airborne solids, liquids and gases will evolve when this
material undergoes pyrolysis or combustion. Carbon Monoxide, Carbon Dioxide
and other unidentified organic compounds may be formed upon combustion.
--------------------------------------------------------------------------------
SECTION 11 TOXICOLOGICAL INFORMATION
--------------------------------------------------------------------------------
Acute Toxicity
Dermal LD50 >2 g/kg(Rabbit) OSHA: Non-Toxic Based on components(s)
Oral LD50 >2 g/kg(Rat) OSHA: Non-Toxic Based on components(s)
Carcinogenicity Classification
Synthetic Gear Oil
NTP: No IARC: Not Reviewed by IARC ACGIH: No OSHA: No
--------------------------------------------------------------------------------
SECTION 12 ECOLOGICAL INFORMATION
--------------------------------------------------------------------------------
Environmental Impact Summary:

There is no ecological data available for this product. However, this product
is an oil. It is persistent and does not readily biodegrade. However, it
does not bioaccumulate.
--------------------------------------------------------------------------------
SECTION 13 DISPOSAL CONSIDERATIONS
--------------------------------------------------------------------------------
RCRA Information:
Under RCRA, it is the responsibility of the user of the material to determine,

at the time of the disposal, whether the material meets RCRA criteria for
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X38 Cone Crusher
hazardous waste. This is because material uses, transformations, mixtures,

processes, etc. may affect the classification. Refer to the latest EPA, state
and local regulations regarding proper disposal.
--------------------------------------------------------------------------------
SECTION 14 TRANSPORT INFORMATION
--------------------------------------------------------------------------------
US Department of Transportation Classification

This material is not subject to DOT regulations under 49 CFR Parts 171-180.
Oil: This product is an oil under 49CFR (DOT) Part 130. If shipped by rail or
highway in a tank with a capacity of 3500 gallons or more, it is subject to
these requirements. Mixtures or solutions containing 10% or more of this
product may also be subject to this rule.
International Air Transport Association

Not regulated under IATA rules.
International Maritime Organization Classification

Not regulated under International Maritime Organization rules.
--------------------------------------------------------------------------------
SECTION 15 REGULATORY INFORMATION
--------------------------------------------------------------------------------
FEDERAL REGULATORY STATUS
OSHA Classification:
Product is hazardous according to the OSHA Hazard Communication Standard, 29
CFR 1910.1200, because it carries the occupational exposure limit for mineral
oil mist.
Ozone Depleting Substances (40 CFR 82 Clean Air Act):

This material does not contain nor was it directly manufactured with any Class
I or Class II ozone depleting substances.
Superfund Amendment & Reauthorization Act (SARA) Title III:
There are no components in this product on the SARA 302 list.
SARA Hazard Categories (311/312):

Immediate Health:NO Delayed Health:NO Fire:NO Pressure:NO
Reactivity:NO
SARA Toxic Release Inventory (TRI) (313):

There are no components in this product on the SARA 313 list.
Toxic Substances Control Act (TSCA) Status:

All component(s) of this material is(are) listed on the EPA/TSCA Inventory of
Chemical Substances.
Other Chemical Inventories:

Component(s) of this material is (are) listed on the Australian AICS,
Canadian DSL, European EINECS,
State Regulation
This material is not regulated by California Prop 65, New Jersey Right-to-Know
Chemical List or Pennsylvania Right-To-Know Chemical List. However for
details on your regulation requirements you should contact the appropriate
agency in your state.
--------------------------------------------------------------------------------
SECTION 16 OTHER INFORMATION
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--------------------------------------------------------------------------------
Revision#: 1
Revision Date: 12/17/2003
Revisions since last change (discussion): This Material Safety Data Sheet
(MSDS) has been newly created to fully comply with the guidance contained in
the ANSI MSDS standard (ANSI Z400.1-1998). We encourage you to take the
opportunity to read the MSDS and review the information contained therein.
--------------------------------------------------------------------------------
SECTION 17 LABEL INFORMATION
--------------------------------------------------------------------------------
READ AND UNDERSTAND MATERIAL SAFETY DATA SHEET BEFORE HANDLING OR DISPOSING OF
PRODUCT. THIS LABEL COMPLIES WITH THE REQUIREMENTS OF THE OSHA HAZARD
COMMUNICATION STANDARD (29 CFR 1910.1200) FOR USE IN THE WORKPLACE. THIS LABEL
IS NOT INTENDED TO BE USED WITH PACKAGING INTENDED FOR SALE TO CONSUMERS AND
MAY NOT CONFORM WITH THE REQUIREMENTS OF THE CONSUMER PRODUCT SAFETY ACT OR
OTHER RELATED REGULATORY REQUIREMENTS.
PRODUCT CODE(S): 65569
Omala® Fluid HD 150
ATTENTION!
PROLONGED OR REPEATED SKIN CONTACT MAY CAUSE OIL ACNE OR DERMATITIS.
Precautionary Measures:
Avoid prolonged or repeated contact with eyes, skin and clothing. Wash
thoroughly after handling.
FIRST AID
Inhalation: Remove victim to fresh air and provide oxygen if breathing is

difficult. Get medical attention.
Skin Contact: Remove contaminated clothing and shoes and wipe excess from
skin. Flush skin with water, then wash with soap and water. If irritation
occurs, get medical attention. Do not reuse clothing until cleaned.
Eye Contact: Flush with water. If irritation occurs, get medical attention.
Ingestion: Do not induce vomiting. In general, no treatment is necessary
unless large quantities of product are ingested. However, get medical
attention.
FIRE
In case of fire, Use water fog, 'alcohol foam', dry chemical or carbon
dioxide (CO2) to extinguish flames. Do not use a direct stream of water.
Material will float and can be re-ignited on surface of water.
SPILL OR LEAK
Dike and contain spill.
FOR LARGE SPILLS: Remove with vacuum truck or pump to storage/salvage vessels.
FOR SMALL SPILLS: Soak up residue with an absorbent such as clay, sand or
other suitable material. Place in non-leaking container and seal tightly for
proper disposal.
CONTAINS: Synthetic hydrocarbon base oil (PAO), Mixture; Polymer additives,

Proprietary
NFPA Rating (Health, Fire, Reactivity): 0, 1, 0
TRANSPORTATION
US Department of Transportation Classification
This material is not subject to DOT regulations under 49 CFR Parts 171-180.
P 76 f 77 A di D

X38 Cone Crusher
Oil: This product is an oil under 49CFR (DOT) Part 130. If shipped by rail or
highway in a tank with a capacity of 3500 gallons or more, it is subject to
these requirements. Mixtures or solutions containing 10% or more of this
product may also be subject to this rule.
CAUTION: Misuse of empty containers can be hazardous. Empty containers can

be hazardous if used to store toxic, flammable, or reactive materials.
Cutting or welding of empty containers might cause fire, explosion or toxic
fumes from residues. Do not pressurize or expose to open flames or heat.
Keep container closed and drum bungs in place.
Name and Address

SOPUS Products
P.O. Box 4453
Houston, TX 77210-4453
ADMINISTRATIVE INFORMATION
MANUFACTURER ADDRESS: SOPUS Products, P.O. Box 4453, Houston, TX.
77210-4453
Company Product Stewardship & Regulatory Compliance Contact: Timothy W Childs
Phone Number: (281) 874-7708
THE INFORMATION CONTAINED IN THIS DATA SHEET IS BASED ON THE DATA AVAILABLE TO
US AT THIS TIME, AND IS BELIEVED TO BE ACCURATE BASED UPON THAT : IT IS
PROVIDED INDEPENDENTLY OF ANY SALE OF THE PRODUCT, FOR PURPOSE OF HAZARD
COMMUNICATION. IT IS NOT INTENDED TO CONSTITUTE PRODUCT PERFORMANCE
INFORMATION, AND NO EXPRESS OR IMPLIED WARRANTY OF ANY KIND IS MADE WITH
RESPECT TO THE PRODUCT, UNDERLYING DATA OR THE INFORMATION CONTAINED HEREIN.
YOU ARE URGED TO OBTAIN DATA SHEETS FOR ALL PRODUCTS YOU BUY, PROCESS, USE OR
DISTRIBUTE, AND ARE ENCOURAGED TO ADVISE THOSE WHO MAY COME IN CONTACT WITH
SUCH PRODUCTS OF THE INFORMATION CONTAINED HEREIN.
TO DETERMINE THE APPLICABILITY OR EFFECT OF ANY LAW OR REGULATION WITH RESPECT

TO THE PRODUCT, YOU SHOULD CONSULT WITH YOUR LEGAL ADVISOR OR THE APPROPRIATE
GOVERNMENT AGENCY. WE WILL NOT PROVIDE ADVICE ON SUCH MATTERS, OR BE
RESPONSIBLE FOR ANY INJURY FROM THE USE OF THE PRODUCT DESCRIBED HEREIN. THE
UNDERLYING DATA, AND THE INFORMATION PROVIDED HEREIN AS A RESULT OF THAT DATA,
IS THE PROPERTY OF SOPUS PRODUCTS AND IS NOT TO BE THE SUBJECT OF SALE OR
EXCHANGE WITHOUT THE EXPRESS WRITTEN CONSENT OF SOPUS PRODUCTS.
37911-10910-100R-12/17/2003
P 77 f 77 A di D

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X38 Cone Crusher
Heavy Component Weights
Part Number & Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Weight

1. Concave ring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 726
2. Smithbond for concave ring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
3. Head and shaft assembly, including taper head, main shaft, shaft nut,
burning ring and mantle. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2048
4. Taper head only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1034
5. Main (tapered) shaft only- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 290
6. Mantle only - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 601
7. Smithbond for mantle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
8. Countershaft box assembly, including countershaft box, bevel pinion,
countershaft and roller bearings. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 521
9. Countershaft box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 408
10. Countershaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
11. Bevel pinion gear (countershaft) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
12. Flywheel sheave - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 145
13. Power rotator assembly, including motor, gearbox and adapter plate. - - - - 106
14. Power rotator mounting bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
15. Power rotator pinion gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
16. Crusher ring gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 175
17. Drive ring weldment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 435
Ver: BKX38-EN-00001 Appendix E Page 577

X38 Cone Crusher
Page 578 Appendix E Ver: BKX38-EN-00001

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X38 Cone Crusher

Operating and Maintenance Manual

Manufactured by: Extec Screens & Crushers Ltd

Ver: BKX38-EN-00001 Operating and Maintenance Manual 25 January 2008

Page ii Introduction Ver: BKX38-EN-00001

Supply of Machinery Safety Regulations - Machinery Directive 98/37/EC

Ver: BKX38-EN-00001 Certificate of Conformity Page iii

Name of manufacturer or supplier

Full postal address including country of origin

Name, type or model, batch or serial number

Place of issue Extec Screens & Crushers Ltd

Name of authorized representative Andy Hall

Position of authorized representative Production Manager

Signature _____________________ Date

Page iv Certificate of Conformity Ver: BKX38-EN-00001

Operating and Maintenance Manual

Ver: BKX38-EN-00001 Contents Page v

1.13.6 Safety Considerations During Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 14

Description and Technical Information

Commissioning and Operation

Page vi Contents Ver: BKX38-EN-00001

4.3.1 Cold Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Trouble Shooting Guide

Ver: BKX38-EN-00001 Contents Page vii

Parts Manual (see book Ver: BKX38-EN-00001) ....................................................................83-176

OEM Manuals supplied with this machine . . . . . . . . . . . . . 177

Models 38, 44, 52, 57 and 68 SBS Cone Crushers

Page viii Contents Ver: BKX38-EN-00001

PRECAUTIONARY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Ver: BKX38-EN-00001 Contents Page ix

LUBRICATION SYSTEM TROUBLESHOOTING SAFETY PRECAUTIONS . . . . . . . . . . . . . . 326

Page x Contents Ver: BKX38-EN-00001

SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

Ver: BKX38-EN-00001 Contents Page xi

Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497

Heavy Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 577

Page xii Contents Ver: BKX38-EN-00001

Section 1 Safety Instructions

1.1 Safety Esstentials

b. This equipment is manufactured in accordance with the Machinery Directive 98/37/

1. Directive 98/37/EC of 22.06.98 (OJ n° L 207 of 23.07.98, p.1)

Ver: BKX38-EN-00001 Safety Instructions Page 1

1.2 Safety Signs and Labels

1.3 Safety Hazards Pertaining to the Equipment

d. Make sure replacement parts include safety instructions and labels.

Page 2 Safety Instructions Ver: BKX38-EN-00001

1.3.1 Symbols for Mandatory Actions

Wear Safety Gloves Wear Eye Protection Wear Safety Helmet

Wear Safety Harness Wear Ear Protection Wear Safety Boots

Disconnect Power Source From Switch Off and Lockout

Read the Manual

Ver: BKX38-EN-00001 Safety Instructions Page 3

1.3.2 Symbols for Prohibited Actions

No Climbing No Smoking Do Not Touch

No Open Flames Limited or Restricted Access Do Not Weld

Do Not Remove Safety Guard

1.3.3 Hazard Symbols

Crushing Hazard - Hands Crushing Hazard - Feet Chemical Burn Hazard

Page 4 Safety Instructions Ver: BKX38-EN-00001

Entanglement Hazard Falling Hazard Falling Load Hazard

Hazardous or Poisonous Material

Lifiting Hazard Skin Injection Hazard Silica or Other Dust Hazard

Trip Hazard Magnet Hazard